02 Error Code Troubleshooting

Chapter 2: Error Code Troubleshooting
Contents
How Error Codes Function ............................................................................................................3
Active System Errors and Error Log Screen Description...........................................................3
Error Log Screen .................................................................................................................3
Error Codes/Solutions Cross Reference Table ...........................................................................5
Error Code Solution Tables .........................................................................................................23
02/18/04 Dimension® Xpand™ Service Manual 2-1

Chapter 2: Error Code Troubleshooting Dimension® Xpand™ Service Manual
2-2 Dimension® Xpand™ Service Manual 02/18/04

Chapter 2: Error Code Troubleshooting
How Error Codes Function
®
The Dimension Xpand™ clinical chemistry system display has a line near the top of the screen that is
devoted to active error messages. Pressing the Alt/M key combination within any software screen will
display useful information to help resolve the error condition currently displayed. In addition, the software
has two programs, Active Errors and Error Log, that enable you to review all errors that have recently
occurred.
Major Error Messages
When the system detects an error condition, the alarm sounds and the active major error
message is displayed below the segment and operating conditions status areas on the screen.
The system can display only one active error message at a time. If more than one error condition
occurs at the same time, the system uses a priority ranking to determine which one to display.
Some error messages will stop system processing; others will not. If system processing stops,
you will need to press the Reset key to clear the active error message and resume processing.
Minor Errors Messages
Each major error message has one or more minor error messages associated with it. These
minor error messages are not displayed automatically and will provide more specific information
about the error that occurred. Additionally, each minor error message corresponds to a three-digit
error code. For example, the error message Bad Cuvette can have any of the following minor
errors:
[258] Cuvette air pressure too high [260] Cuvette not sealed
[259] Cuvette air pressure too low [261] Heat torch timed out
Because each of these situations requires a unique remedy, it is important that you pay close
attention to these minor errors and the associated error code number. Although each minor error
message has a specific error code number, many of these tables combine groups of common
error codes with the same general message—the only difference is the name of the module
(“module name”) that is affected. For example, error code 004 is “Sample probe sensor problem
or probe did not move,” and error code 016 is “Sample 100 µL syringe pump sensor problem or
syringe did not move.” The solution for both error codes 004 and 016 is in table 2-2.
Refer to Table 2-1. Cross Reference of Error Codes, Messages, and Solution Tables for a
complete cross-reference sorted by error code, which lists the solution table for each code.
Active System Errors and Error Log Screen Description

The Active Errors screen shows all the error messages that have occurred since the last time the
Reset key was pressed. Pressing Reset deletes the Active Errors screen list. This screen shows
the priority of the error message and a code that identifies the minor error that caused the error
message. Help screens will be displayed for most active errors by pressing Alt/M. These screens
include minor error code messages, explanations, and basic operator troubleshooting solutions.
Error Log Screen

In addition to the major error message and code, the Error Log screen (see next page) shows the
time each error message occurred and the method (if any) associated with the error. The log
shows the last 50 major error messages.

F3: SEE MINOR

The minor error is displayed in the lower portion of the screen when you select any error
message in the log (use up/down arrow keys) and press F3.
F5: MORE INFO
After selecting any error message in the log (using up/down arrow keys) and pressing F5 you will
view a Help screen for that error. Help screens are identical to those displayed when Alt/M is
used for the currently displayed “active” error.
F6: ERROR CODE
Pressing F6 will prompt the user to enter a specific 3-digit error code. Typing any valid 3-digit
error code and pressing Enter will display a help screen identical to those displayed when Alt/M
is used for the currently displayed “active” error. The selected 3-digit code does not have to be
present in the error log.
To help locate information about troubleshooting a problem, the table below cross references the
error code and associated major and minor error messages. The third column references the
table (in this chapter) you should use to troubleshoot the problem.

Dimension® Xpand™ Service Manual Chapter 2: Error Code Troubleshooting
Error Codes/Solutions Cross Reference Table
Table 2-1. Cross Reference of Error Codes, Messages, and Solution Tables
Error Messages Troubleshooting
Error Code
(Major followed by Minor) Table
001 This error does not apply to Dimension® Xpand™
002 Sample Probe Cannot Find Home 2-3
Sample probe sensor did not turn on or probe did not move (cfh)
004 Sample Probe Cannot Find Home 2-2
Sample probe sensor problem or probe did not move (soh)
005 Sample Probe Lost Steps 2-4
Sample probe lost steps (mfh)
Sample probe lost steps (mth)
007–013 These errors do not apply to Dimension® Xpand™
014 Sample Metering Pump Cannot Find Home 2-3
Sample 100 µL syringe pump sensor did not turn on or syringe did not move (cfh)
016 Sample Metering Pump Cannot Find Home 2-2
Sample 100 µL syringe pump sensor problem or syringe did not move (soh)
017 Sample Metering Pump Lost Steps 2-4
Sample 100 µL syringe lost steps (mfh)
Sample 100 µL syringe lost steps (mth)
020 Reagent 2 Metering Pump Cannot Find Home 2-3
R2 500 µL syringe pump sensor did not turn on or syringe did not move (cfh)
R2 500 µL syringe pump sensor problem or syringe did not move (soh)
023 Reagent 2 Metering Pump Lost Steps 2-4
Reagent 2 small pump lost steps (mfh)
Reagent 2 small pump lost steps (mth)
026 Sample Arm Cannot Find Home 2-3
Sample arm sensor did not turn on or arm did not move (cfh)
028 Sample Arm Cannot Find Home 2-2
Sample arm sensor problem or arm did not move (soh)
029 Sample Arm Lost Steps 2-4
Sample arm lost steps (mfh)
Sample arm lost steps (mth)
032 Photometer Cannot Find Home 2-3
Photometer sensor did not turn on or photometer did not move (cfh)
Photometer sensor problem or photometer did not move (soh)
035 Photometer Lost Steps 2-4
Photometer lost steps (mfh)
Photometer lost steps (mth)

Table 2-1. Cross Reference of Error Codes, Messages, and Solution Tables (contd.)
Error Code
038 Sample Flush Pump Cannot Find Home 2-3
Sample 2.5 mL syringe pump sensor did not turn on or syringe did not move (cfh)
040 Sample Flush Pump Cannot Find Home 2-2
Sample 2.5 mL syringe pump sensor problem or syringe did not move (soh)
041 Sample Flush Pump Lost Steps 2-4
Sample 2.5 mL syringe pump lost steps (mfh)
Sample 2.5 mL syringe pump lost steps (mth)
044 Reagent 2 Flush Pump Cannot Find Home 2-3
R2 2.5 mL syringe pump sensor did not turn on or syringe did not move (cfh)
R2 2.5 mL syringe pump sensor problem or syringe did not move (soh)
047 Reagent 2 Flush Pump Lost Steps 2-4
R2 2.5 mL syringe pump lost steps (mfh)
R2 2.5 mL syringe pump lost steps (mth)
050 Reagent 2 Arm Cannot Find Home 2-3
R2 arm sensor did not turn on or arm did not move (cfh)
052 Reagent 2 Arm Lost Steps 2-2
R2 arm sensor problem or R2 arm did not move (soh)
R2 arm lost steps (mfh)
R2 arm lost steps (mth)
056 Segment Wheel Cannot Find Home 2-3
Segment wheel sensor did not turn on or carousel did not move (cfh)
058 Segment Wheel Cannot Find Home 2-2
Segment wheel sensor problem or segment wheel did not move (soh)
059 Segment Wheel Lost Steps 2-4
Segmented wheel lost steps (mfh)
060 Segment Wheel Lost Steps 2-4
Segmented wheel lost steps (mth)
061 Cuvette Wheel Cannot Find Position 2-60
Cuvette wheel sensor problem or cuvette wheel did not move (sop)
Cuvette wheel sensor problem or cuvette wheel did not move (cfp)
063 Cuvette Board Communication Problem 2-6
Cuvette wheel illegal error code
Cuvette wheel sensor problem or cuvette wheel did not move (soh)
067 Communication Problem 2-6
Flex loader sensor problem or flex loader did not move (sop)
Auto loader sensor did not turn on or loader did not move (cfh)
Auto loader bad speed sequence
070 Auto Reagent Cartridge Loader Has Lost Steps 2-2
Flex loader sensor problem or flex loader did not move (soh)

Error Code
Auto loader lost steps moving into the reagent carousel
Auto loader lost steps moving back to home
074 Reagent 2 Probe Cannot Find Home 2-3
R2 probe sensor did not turn on or probe did not move (cfh)
R2 probe sensor problem or R2 probe did not move (soh)
077 Reagent 2 Probe Lost Steps 2-4
R2 probe lost steps (mfh)
R2 probe lost steps (mth)
080 Reagent 2 Carriage Cannot Find Home 2-3
R2 carriage sensor did not turn on or carriage did not move (cfh)
R2 carriage sensor problem or carriage did not move (soh)
083 Reagent 2 Carriage Lost – Possible Contamination 2-4
R2 carriage lost steps (mfh)
R2 carriage lost steps (mth)
Cuvette and IOC4 stuck on position
Cuvette and IOC4 cannot find home
Cuvette and IOC4 illegal error code
Cuvette and IOC4 stuck on home
Cuvette and IOC4 lost steps moving from home
Cuvette and IOC4 lost steps moving to home
R1 2.5 mL syringe pump sensor did not turn on or syringe did not move (cfh)
R1 2.5 mL syringe pump sensor problem or syringe did not move (soh)
R1 2.5 mL syringe pump lost steps (mfh)
R1 2.5 mL syringe pump lost steps (mth)
R1 carriage sensor did not turn on or carriage did not move (cfh)
R1 carriage sensor problem or R1 carriage did not move (soh)
119 Reagent 1 Carriage Lost Steps 2-4
R1 carriage lost steps (mfh)
R1 carriage lost steps (mth)

Error Code
122 Reagent Carousel Cannot Find Home 2-3, 2-42
Reagent carousel sensor did not turn on or carousel did not move (cfh)
124 Reagent Carousel Cannot Find Home 2-2, 2-42
Reagent tray sensor problem or tray did not move (soh)
125 Reagent Carousel Lost Position 2-4, 2-42
Reagent tray lost steps (mfh)
126 Reagent Carousel Lost Position 2-4, 2-42
Reagent tray lost steps (mth)
R1 500 µL syringe pump sensor did not turn on or syringe did not
move (cfh)
R1 500 µL syringe pump sensor problem or syringe did not move (soh)
R1 500 µL syringe pump lost steps (mfh)
R1 500 µL syringe pump lost steps (mth)
Reagent 1 probe cannot find home
R1 probe sensor problem or probe did not move (soh)
R1 probe lost steps (mfh)
R1 probe lost steps (mth)
145 Sample Probe Communication Problem 2-6
Sample probe communication error
146 Cannot Communicate to IO Boards 2-5
Sample probe board test failed
147 System Error 2-7
Sample probe system problem
148 Sample Probe Communication Problem 2-6
Sample probe timeout on IOC read
153 Sample Metering Pump Communication Problem 2-6
Sample small pump communication error
Sample small pump board test failed
Sample small pump system problem
156 Sample Metering Pump Communication Problem 2-6
Sample small pump timeout on IOC read
157 Reagent 2 Metering Pump Communication Problem 2-6
Reagent 2 small pump communication error
Reagent 2 small pump board test failed
Reagent 2 small pump system problem
Reagent 2 small pump timeout on IOC read
161 Sample Arm Communication Problem 2-6
Sample arm communication error
Sample arm board test failed

Error Code
Sample arm system problem
164 Sample Arm Communication Problem 2-6
Sample arm timeout on IOC read
165 Photometer Communication Problem 2-6
Photometer communication error
Photometer board test failed
Photometer system problem
168 Photometer Communication Problem 2-6
Photometer communication error
169 Sample Flush Pump Communication Problem 2-6
Sample large pump communication error
Sample large pump board test failed
Sample large pump system problem
172 Sample Flush Pump Communication Problem 2-6
Sample large pump communication error
173 Reagent 2 Flush Pump Communication Problem 2-6
Reagent 2 large pump communication error
Reagent 2 large pump board test failed
Reagent 2 large pump system problem
Reagent 2 large pump timeout on IOC read
177 Reagent 2 Arm Communication Problem 2-6
Reagent 2 arm communication error
Reagent 2 arm board test failed
Reagent 2 arm system problem
180 Reagent 2 Arm Communication Problem 2-6
Reagent 2 arm timeout on IOC read
181 Sample Carousel Communication Problem 2-6
Sample carousel communication error
Sample carousel board test failed
Sample carousel system problem
184 Sample Carousel Communication Problem 2-6
Sample carousel timeout on IOC read
185 Cuvette Wheel Communication Problem 2-6
Cuvette wheel communication error
Cuvette wheel board test failed
Sample carousel system problem
188 Cuvette Wheel Communication Problem 2-6
Cuvette wheel timeout on IOC read
Cuvette board IOC 4 communication error
Cuvette board IOC 4 board test failed
Cuvette board IOC 4 system problem
Cuvette board IOC 4 timeout on IOC read

Error Code
193 Reagent 2 Probe Communication Problem 2-6
Reagent 2 probe communication error
Reagent 2 probe board test failed
Reagent 2 probe system problem
Reagent 2 probe timeout on IOC read
197 Reagent 2 Carriage Communication Problem 2-6
Reagent 2 carriage communication error
Reagent 2 carriage board test failed
Reagent 2 carriage system problem
Reagent 2 carriage timeout on IOC read
Reagent 1 flush pump communication error
Reagent 1 flush pump board test failed
Reagent 1 flush pump system problem
Reagent 1 flush pump timeout on IOC read
Reagent 1 carriage communication error
Reagent 1 carriage board test failed
Reagent 1 carriage system problem
Reagent 1 carriage timeout on IOC read
225 Reagent Carousel Communication Problem 2-6
Reagent carousel communication error
Reagent carousel board test failed
Reagent carousel system problem
228 Reagent Carousel Communication Problem 2-6
Reagent carousel timeout on IOC read
229 IMT Pump Communication Problem 2-6
IMT peristaltic pump communication error

Error Code
IMT peristaltic pump board test failed
IMT peristaltic pump system problem
232 IMT Pump Communication Problem 2-6
IMT peristaltic pump timeout on IOC read
Reagent 1 meter pump communication error
Reagent 1 meter pump board test failed
Reagent 1 meter pump system problem
Reagent 1 meter pump timeout on IOC read
Reagent 1 probe communication error
Reagent 1 probe board test failed
Reagent 1 probe system problem
Reagent 1 probe timeout on IOC read
241 IOC Communication Problem 2-6
Communication error
Board test failed
System problem
Timeout on IOC read
Reagent 2 probe lost steps seeking home
Reagent 2 arm lost steps seeking home
Reagent 2 carriage lost steps seeking home
Photometer lost steps seeking home
Sample probe lost steps seeking home
Sample arm lost steps seeking home
Sample small pump lost steps seeking home
Sample large pump lost steps seeking home
Reagent 2 small pump lost steps seeking home
Reagent 2 large pump lost steps seeking home
255-256 These errors do not apply to Dimension® Xpand™
Cuvette wheel index error
258 Bad Cuvette 2-57
Cuvette air pressure too high
Cuvette air pressure too low
Cuvette not sealed

Error Code
Heat torch timed out
262 Cuvette Failed Photometric QC Check 2-19
Bad cuvette QC
263 Cuvette Cartridge Out of Film 2-18
Cuvette film end of roll detected
264 Temperature Out of Range 2-43
Cuvette temperature out of range
265 Bad Cuvettes Repeatedly Formed 2-17
Three bad cuvettes sequentially formed
266 Reagent Carousel Mispositioned 2-35
Reagent carousel incorrect transition count
267 Serious Inventory Error – Check With Prime Operator 2-42
Reagent carousel not on home when expected
268 Reagent Carousel Home Sensor Failure 2-2
Reagent carousel home detected at 2 positions
271 Unable to Get Photometer Reading 2-45
Photometer A to D problem
272 Photometer Readings Underrange 2-30
Photometer readings underrange
276 Photometer Mispositioned 2-28
Photometer gross positioning error
277 Photometer Mispositioned 2-28
Photometer fine positioning error
278 Photometer Source Lamp Problem Press Alt/M 2-31
Photometer source lamp off detected
Photometer cannot find correct home phase
280 Photometer Failed to Align 2-26
Photometer cannot find negative reading
281 Photometer Failed to Align 2-26
Photometer cannot find positive reading
284 Unable to Establish Cuvette QC Limits 2-91
Cannot establish cuvette QC limits
285 Sample Carousel Mispositioned 2-101
Sample carousel incorrect transition count
290 Insufficient Vacuum in Waste System 2-24
Vacuum not active during IMT activity
Vacuum not active during reagent activity
292 Reagent Lid Open 2-36
Reagent lid open detected during initialize or processing
Illegal cuvette number for reagent delivery
Incorrect cartridge for reagent aspiration or preparation
296 Reagent 2 Ultrasonic Unable to Mix 2-34
Faulty reagent ultrasonic mix
298 Sampler Ultrasonic Unable to Mix 2-41
Faulty sample ultrasonic mix
300 Waste Bottle Full 2-46
Waste sensor active

Error Code
301 Water Bottle Empty 2-49
Low water sensor active
302 IMT A to D Timeout 2-102
IMT A to D timeout
303 IMT Measurement Error 2-8
Sodium electrode unstable
Potassium electrode unstable
Chloride electrode unstable
Sodium electrode drift
Potassium electrode drift
Chloride electrode drift
311 IMT Sample Fluid Detect Failure 2-13
IMT air detected when fluid expected
312 IMT Standard Fluid Detect Failure 2-13
IMT air detected when fluid expected
313 IMT Sample Air Detect Failure 2-14
IMT fluid detected when air expected
314 IMT Standard Air Detect Failure 2-14
IMT fluid detected when air expected
315 Module Deconfigured 2-25
Cannot process HM/IMT tests if module deconfigured
317 LIS/Host Communication Problem 2-9
LIS/host communication port receiver error
Received fourth NAK from LIS/host
Received invalid message from LIS/host
Did not receive acceptance message from LIS/host
Did not receive ACK or NAK from LIS/host
322 LIS/Host Result Rejected 2-9
LIS/host rejected results 50 times
Received fourth ENQ from LIS/host
Reagent carousel lost
328 Module Recovering 2-10
Reagent critical time missed
Sample critical time missed
Reagent 2 block time missed
Sampler block time missed
Reagent carousel block time missed
Photometer block time missed

Error Code
336 Module Not Ready 2-10
Cuvette block time missed
337 Module Not Ready 2-10
Sample carousel block time missed
IMT block time missed
339 Segment Aborted Press Alt/M 2-90
User aborted a segment
340 User Aborted Processing 2-96
User pressed interrupt key
345 Fatal System/Disk Error 2-21
Could not open I/O driver
CSP error
Unknown motor ID
Unknown IOC error code
353 Floppy Not Ready 2-15, 2-21
Could not open file
354 Fatal System/Disk Error 2-15, 2-21
Could not open IMP
Bad IMP write
Bad IMP read
361 Failed to Read File from Disk 2-15
Failed on file read
Failed on file long read
Failed to read checksum value
364 Disk File Checksum Error 2-15
Checksum error on disk files
366 Failed to Write File to Disk 2-15
Failed on disk file write
Failed on disk file long write
Failed to write checksum value
Fatal system signal caught
371 Unable to Form Cuvettes 2-44
Heat torch thermocouple open
372 Printer Off Line 2-32
Printer off line
377 Sample Carousel Mispositioned 2-39
Incorrect sample position for colorimetric analysis
378 Required Segment Not In Position 2-39
Incorrect sample position for IMT analysis

Error Code
381 Reagent Preparation Error 2-37
Process error during preparation
382 Reagent Preparation Error 2-38
Prepared reagent failed quality assurance
383 Insufficient IMT Consumables Press Alt/M 2-23
IMT consumable required
384 IMT Failed to Calibrate 2-12
IMT failed autocalibration
389 Insufficient Sample 2-82, 2-83
Photometric sampler cannot reach the sample
390 No Sample Found During Level Sense 2-82, 2-83
No sample
Reagent 1 probe lost steps seeking home
Reagent 1 carriage lost steps seeking home
Reagent 1 small pump lost steps seeking home
Reagent 1 large pump lost steps seeking home
398 Reagent 1 Ultrasonic Unable to Mix 2-33
Faulty reagent 1 ultrasonic mix
399 Water Bottle Cable Disconnected 2-47
Hi and low water sensors simultaneously active
400 Water Bottle Failed to Fill 2-48
Timeout occurred before high water sensor active
401 Reagent 2 Unable to Recover 2-11
Reagent 2 failed to recover after process error
402 Reagent 1 Unable to Recover 2-11
Reagent 1 failed to recover after process error
403 Sampler Unable to Recover 2-11
Sampler failed to recover after process error
404 IMT Module Unable to Recover 2-11
IMT module failed to recover after process error
Filter wheel position sensor not received
Filter wheel home sensor not received
Filter wheel not spinning or speed incorrect
No measurement signal
415 Photometer Measurement Check Failed 2-27
Photometric QC readings not stable
Illegal cuvette number for sample delivery
417 Sample Carousel Moved on Instrument 2-101
Sample carousel moved by user
418 Sample Carousel Bumped 2-101
Sample carousel slight movement detected
419 Slow Heat Torch Warm-up 2-16
Heat torch warm-up exceeded allotted time—cuvette not used

Error Code
Reagent 1 block time missed
422 External Printer Off Line 2-78
External printer unable to receive data
423 Backup Battery Low 2-100
Low battery voltage – schedule maintenance
Unknown error code
No reference signal
Air compressor not on
Heat torch heater open
Heat torch A/D error
441 Sample Arm Mispositioned 2-88
Sample arm gross positioning error
Sample arm fine positioning error
443 24 Volts Not Functional 2-74
24 volts would not turn on
Vacuum not active during IMT activity
464 Required Segment Not in Position 2-87
Incorrect sample position for segment to AW aspiration
Incorrect sample position for level sense
Incorrect sample position for IMT dilution aspiration
IMT aliquot critical time missed
IMT dilution aliquot critical time missed
IMT photo dilution carousel critical time missed
IMT—module critical time missed
472 Insufficient Sample for Ordered Tests 2-82, 2-83
Insufficient sample for ordered tests
473 System Printer Power Is Off 2-61
Printer power appears to be off
474 System Printer Paper Is Empty 2-62
Check system printer—Paper empty light is on
475 System Printer Error Light Is On 2-63
Check system printer—Error light is on
476 Photometer Cannot Access Cuvette 2-84
Photometer cannot read past position 63
477 Photometer Unable to Initialize 2-86
Photometer needs dark current calibration
478 Photometer Outer/Inner Detector Error 2-85
Photometer cannot turn outer detector on/off
479 Photometer Outer/Inner Detector Error 2-85
Photometer inner/outer readings out of range

Error Code
Photometer needs source lamp calibration
Photometer needs mAU offset calibration
Photometer needs dark and lamp and mAU offsets calibration
484 Error in Setting Up Bar Coded Tube Sample 2-9, 2-77
Host computer off line
Host computer unable to respond
Sample memory limit exceeded. Try again later
487 Error in Setting Up Bar Coded Tube Sample 2-77
Result memory limit exceeded. Try again later
Bar coded sample lacks any sample ID information
Bar coded sample lacks sample number
Bar coded sample lacks sample fluid type
Bar coded sample lacks test method type
LIS/host unknown error code
Bar coded tube found at an already assigned position
Thermal chamber control temperature problem
Thermal chamber heater open
Ambient compensation temperature problem
Cuvette ring temperature problem
Cuvette ring cooling fan motor problem
Reagent tray temperature problem
500 IMT Fatal Measurement Error 2-103
IMT A to D drifting
501 IMT Fatal Measurement Error 2-103
IMT invalid test frequency
502 Segment Aborted 2-75
Processing segment has been replaced with a new segment
Bar coded tube on processing segment has been replaced
Processing segment has been moved
Processing segment has been removed
Processing bar coded tube has been moved
507 User Aborted Processing 2-96
User deleted all processing segments
508 Bad Cuvettes Repeatedly Formed 2-19
Five sequential bad cuvette QCs
IMT calibration not valid

Error Code
IMT in error for test
Cannot reset control boards or start token passing
Cannot initialize (download software to) control boards
515 Auto Cartridge Loader Error 2-104
Cartridge detected during unloading process
Cuvette ring cooling problem
Sampler arm not positioned at expected location
519 System Error – Please Contact the Technical Assistance Center 2-109
Error allocating result buffer
Reagent loader block time missed
Insufficient vacuum detected while monitoring system
538 Sample Aborted 2-75
User aborted a sample
540 IMT Rotary Valve Cannot Find Home 2-52
IMT rotary valve sensor did not turn on or valve did not move
541 IMT Rotary Valve Communication Problem 2-53
IMT rotary valve illegal error code
542 IMT Rotary Valve Cannot Find Home 2-50
IMT rotary valve sensor problem or valve did not move
543 IMT Rotary Valve Lost Steps 2-51
IMT rotary valve lost steps
544 IMT Rotary Valve Lost Steps 2-51
IMT rotary valve lost steps
545 IMT Failed to Detect Flush Fluid 2-54
IMT failed to detect flush fluid
546 Insufficient/Excess IMT Diluent in Port 2-55
Insufficient/excess IMT diluent in port
547 IMT Failed to Auto Align 2-56
Auto align failed to sense Std A alignment fluid
Incubation wheel block time missed
549 Incubation wheel mispositioned 2-80
Incubation wheel incorrect transition count
550 Incubation Wheel Lost While Processing 2-2, 2-79
Incubation wheel not on home when expected
551 Incubation Wheel Home Sensor 2-2
Incubation Wheel home detected at two positions
552 Incubation Wheel Not Detected 2-2
Incubation Wheel home sensor on when not home
553 Incubation Wheel Not Detected 2-2
Incubation Wheel off position at end of motion
554 Incubation Wheel Unable To Recover 2-11
Incubation Wheel failed to recover
Wash Station block time missed

Error Code
556 Wash Probe Lost Steps 2-4
Wash probe lost steps seeking home
557 Wash Station Unable to Recover 2-11
Wash Station failed to recover
558 Wash Wheel Mispositioned 2-99
Wash Wheel incorrect transition count
559-560 This error does not apply to Dimension® Xpand™
561 HM System Not Ready 2-73
Incorrect vessel during HM wash
Incorrect vessel for reagent delivery
Incorrect vessel for sample delivery
565 Vessel Wheel Full 2-98
All vessels allocated – press Reset to restart
566 Reagent Cleaner Bottle Empty 2-72
Low reagent cleaner sensor active
567 Sample Cleaner Bottle Empty 2-72
Low sample cleaner sensor active
568 Reagent Probe Cleaner Not Detected 2-65
Reagent cleaner not detected during system check
569 Sample Probe Cleaner Not Detected 2-65
Sample cleaner not detected during system check
570 Chemistry Wash Bottle Empty 2-72
Low wash buffer sensor active
571-572 This error does not apply to Dimension® Xpand™
573 Sample Probe Mispositioned 2-89
Sample probe gross positioning error
574 Sample Probe Mispositioned 2-89
Sample probe fine positioning error
575 Vessel Transfer Unable to Recover 2-11
Vessel Transfer failed to recover
576 Vessel Track Interference 2-97
Vessel stuck in track during loading
577 Vessel Shuttle Guide Problem 2-67
Vessel shuttle guide stuck, will not engage
578 Vessel Shuttle Guide Problem 2-67
Vessel shuttle guide stuck, will not retract
579 Vessel Transfer Lost Steps 2-4
Vessel Transfer lost steps moving to wash wheel
Vessel Transfer lost steps moving to incubation wheel
581 Check Reaction Vessel Waste – Reset counter 2-68
Check reaction vessel waste – reset counter
Incubation Wheel temperature out of range
583 Vessel Mixer Failure 2-70
Vessel mixer 1 – No revolutions detected
584 Vessel Mixer Failure 2-70
Vessel mixer 2 – No revolutions detected
586 Wash Aspirator Failure 2-71
Vessel aspirator 1 – possible obstruction
588 Wash Aspirator Failure 2-71
Vessel aspirator 2 – possible obstruction
589 Vessel Mixer Unable to Recover 2-11
Vessel mixer failed to recover

Error Code
591 Vessel Transfer Cannot Find Home 2-3
Vessel transfer cannot find home
593 Vessel Transfer Cannot Find Home 2-2
Vessel Transfer stuck on home
Vessel Transfer lost steps moving from home
Vessel Transfer lost steps moving to home
597 Wash Probe Cannot Find Home 2-3
Wash Probe cannot find home
599 Wash Probe Cannot Find Home 2-2
Wash Probe stuck on home
Wash Probe lost steps moving from home
Wash Probe lost steps moving to home
603 Wash Wheel Cannot Find Home 2-3
Wash Wheel cannot find home
605 Wash Wheel Cannot Find Home 2-2
Wash Wheel stuck on home
Wash Wheel lost steps moving from home
Wash Wheel lost steps moving to home
615 Incubation Wheel Cannot Find Home 2-3
Incubation Wheel cannot find home
617 Incubation Wheel Cannot Find Home 2-2
Incubation wheel stuck on home
618 Incubation Wheel Mispositioned 2-4
Incubation wheel lost steps moving from home
619 Incubation Wheel Mispositioned 2-4
Incubation wheel lost steps moving to home
621 Wash Pump Cannot Find Home 2-3
Wash pump cannot find home
623 Wash Pump Cannot Find Home 2-2
Wash pump stuck on home
624 Wash Pump Lost Steps 2-4
Wash pump lost steps moving from home
625 Wash Pump Lost Steps 2-4
Wash pump lost steps moving to home
671 HM Assay Failed Cuvette QC 2-19
HM assay failed cuvette QC
672 Insufficient/Excess IMT Diluent in Port 2-55
Insufficient/excess IMT diluent in port
740 This error does not appear in operation.
742 Diluent Pump Motor Cannot Find Home 2-3
Diluent Pump Motion or Home Sensor Problem (cfh)

Error Code
744 Diluent Pump Motor Cannot Find Home 2-2
Diluent Pump Motion or Home Sensor Problem (soh)
745 Diluent Pump Motor Lost Steps 2-4
Diluent Pump Lost Steps (mfh)
746 Diluent Pump Motor Lost Steps 2-4
Diluent Pump Motor Lost Steps Diluent Pump Lost Steps (mth)
747 Instrument Power Interrupted 2-114
Power to the instrument was interrupted
748 Vessel in Shuttle Not Detected 2-115
Optical sensor failed to detect vessel
749 Vessel Track Empty 2-116
Vessel low level detected
750 Level Sense Error 2-83
Sample Probe Sensed Sample Fluid Level Too Soon during Level Check
751 Level Sense Error 2-112
Sample Probe failed to reliably detect fluid level
752 ACMIA Vessel Failed Fluid Level Detect 2-113
No sample detected in ACMIA test vessel


Error Code Solution Tables
Table 2-2. “[module name] Sensor Problem or Module Did Not Move”
Explanation Probable Causes Error Codes
Control system always sees home signal. • Defective sensor 004, 016, 022, 028, 034, 040, 046, 052,
• Binding or interference with motion of 058, 064, 070, 076, 082, 112, 118, 124,
unit 136, 142, 268, 279, 550, 551, 552, 553,
• Blown fuse 744, 593, 599, 605, 617, 623
• Defective cables or connectors
• Loose or unplugged connectors
• Defective control PC board
Solution
1. Press Reset to initialize the module and observe for the following two steps. Open any lids, doors, or panels as needed to
observe movement.
Warning: Keep hands clear of moving modules!
NOTE: A spare magnet (accessory kit drawer #13) may be used on the reagent lid switch to suppress “Reagent Lid
Open” errors when lifting the reagent lid for observation.
NOTE: If you are troubleshooting any of the three motor control boards, they all have the same part number and are
interchangeable.
2. Does the module move without stopping? If it does, do the following:

a. Locate the sensor LED on the appropriate board using fuse/PC board label on instrument door.
b. If possible, move the module into and out of its home position, checking for the LED to turn on
and off. If it does not turn on and off, replace the sensor.
If the problem still exists, troubleshoot the control PC board or connectors and wiring.
3. Does the module attempt to move, but stops before reaching “Home” ?
If it does:
a. Suspect defective module or wiring.
b. Use motor diagnostics to help determine the module problem.
If it does not move at all (there is no movement):

a. Check fuse A and B boards for blown fuses (fuse LED off), and check the assigned load on
fuse label to verify the fuse’s load corresponds to the module causing the problem.
b. Check for other probable causes (refer to the list above).
c. Go to power diagnostics screen and verify DC voltages are present. If not, check test points on backplane.
d. Check 24v DC inhibit signal from auxiliary PCB (P/J 92) to DC power supply.

Table 2-3. “[module name] Sensor Did Not Turn On or Module Did Not Move (cfh)”
Control system never sees home signal. • Defective sensor 002, 014, 020, 026, 032, 038, 044, 050,
• Binding or interference with motion of 056, 068, 074, 080, 110, 116, 122, 134,
unit 140, 591, 597, 603, 615, 621, 742
• Blown fuse
• Defective control PC board
• Defective cables or connectors
• Loose or unplugged connectors
• Drains overflowing onto sensor
• Tubing leaking onto sensor
Solution
1. Press Reset to initialize the module and observe for the following two steps. Open any lids, doors, or panels as needed to
observe movement.
Warning: Keep hands clear of moving modules!
NOTE: A spare magnet (accessory kit drawer #13) may be used on the reagent lid switch to suppress “Reagent Lid
Open” errors when lifting the reagent lid for observation.
interchangeable.
2. Does the module move without stopping? If it does, do the following:

a. Locate the sensor LED on the appropriate board using fuse/PC board label on instrument door.
b. If possible, move the module into and out of its home position, checking for the LED to turn on
and off. If it does not turn on and off, replace the sensor.
If the problem still exists, troubleshoot the control PC board or connectors and wiring.
3. Does the module attempt to move, but stops before reaching “Home” ?
If it does:
a. Suspect defective module or wiring.
b. Use motor diagnostics to help determine the module problem.
If it does not move at all (there is no movement):

a. Check fuse A and B boards for blown fuses (fuse LED off), and check the assigned load on
fuse label to verify the fuse’s load corresponds to the module causing the problem.
b. Check for other probable causes (refer to the list above).
c. Go to power diagnostics screen and verify DC voltages are present. If not, check test points on backplane.
d. Check 24v DC inhibit signal from auxiliary PCB (P/J 92) to DC power supply.

Table 2-4. “[module name] Lost Steps”

Module took wrong number of steps to or • Photometer 005, 006, 017, 018, 023, 024, 029, 030,
away from home – “D” washers 035, 036, 041, 042, 047, 048, 053, 054,
– Photodiode housing interference 059, 060, 069, 071, 072, 077, 078, 083,
– separation module magnet 084, 113, 114, 119, 120, 125, 126, 137,
– thermal chamber (warped) or 138, 143, 144, 245, 246, 247, 248, 249,
insulation loose 250, 251, 252, 253, 254, 394, 395, 396,
• Dual Pumps 397, 556, 579, 580, 594, 595, 600, 601,
– defective limit switch 606, 607, 618, 619, 624, 625, 745, 746
– low motor torque
– back pressure from defective
valve or kinked tubing
• Belt Tension
• Mechanical binding or interference
• Loose hardware or misaligned
hardware
• Misalignment or drift in alignment
• Loose connections
• Motors–insufficient torque
• Defective sensor
• Crimped tubing
• Lubrication–too much or not enough:
• Auto flex loader:
– failed flex stop solenoid
– flex cartridge already installed in
tray
Solution
1. Observe items listed in Probable Causes (above) and align or repair as necessary.
2. In addition to checking the above items, check for the following if the module has tubing, probes, or needles:
a. clogged tubing, needles, or probes
b. back pressure
3. Use motor diagnostics to further identify the problem.
Table 2-5. “[module name] Board Test Failed”

Board status test fails and the command • Electrical noise 146, 154, 158, 162, 166, 170, 174, 178,
to order a motor motion is not sent. This • Defective control PC board 182, 186, 190, 194, 198, 202, 206, 218,
occurs when the microprocessor sends • software glitch 222, 226, 234, 238, 242
the motor motion command to the control
board.
Solution
1. Press Reset to resume normal operation.
2. Perform a controlled power shutdown.
3. Reseat the board associated with the module having the problem, then power up the instrument.
4. Look at the numbers or letters displayed on the front of the control board and use the table below to determine the problem.
(When software is loaded correctly, the boards should display the following sequence of letters/numbers: F, then boards
change to 0, then D, then to 1.)
Hex No. Description

0 No error; code not downloaded; ROM code active
1 No error; code downloaded and running
2 Error; ROM checksum
3 Error; downloaded code checksum
4 Error; RAM memory (6000–FFFE) error
5 Error; low RAM memory (510–1EFE) error
6 Error; stack overflow
7 Error; application specific (currently unused)
C Error; application specific (currently unused)
E Error; application specific (currently unused)
D Status; software download in progress
F Reset
5. Replace the board if necessary.
interchangeable.

Table 2-6. “Communication Problem or Error” or “Time Out on IOC Read”

Communication Error—While the ! Electrical noise 063, 067, 091, 092, 093, 094, 095,
computer was instructing the instrument ! Defective control PC board 096, 145, 148, 153, 156, 157, 160,
to perform a motion, there was an error 161, 164, 165, 168, 169, 172, 173,
! Software glitch
in the communication stream between 176, 177, 180, 181, 184, 185, 188,
the microprocessor and the control 189, 191, 192, 193, 196, 197, 200,
board. 201, 203, 204, 205, 207, 208, 217,
220, 221, 224, 225, 228, 229, 230,
Time Out—Occurs when the system 232, 233, 236, 237, 240, 241, 244,
detects an error that is not mapped to 349
any expected errors. Software received
a signal for a home or position sensor
that does not exist or for a motor
controller that is not used (spare).
Solution
Hex No. Description

F Reset
interchangeable.

Table 2-7. “System Error or Problem”

The system detects an error that does ! Software glitch 147, 155, 159, 163, 167, 294, 295, 327,
not belong to any of the established error 347, 416
categories. The error message tells
which unit the computer was
communicating with at the time the error
was detected.
Solution
Hex No. Description

F Reset
interchangeable.
Table 2-8. IMT Measurement Error: “Electrode Unstable” or “Electrode Drift”

Each analyte’s sensor has limits on how • QuikLYTE® cartridge interface door 303, 304, 305, 307, 308, 309
quickly the millivolt readings may change is open
over a set period of time. When these • Improper flow of Salt Bridge solution
limits are exceeded, these errors are • QuikLYTE® cartridge interface
posted. electrical connector is disconnected
Solution
1. If sensor drift errors are posted, recalibrate the IMT system and rerun your sample.
2. Check that the QuikLYTE® cartridge interface door is completely closed.
3. Check that there is proper flow of Salt Bridge solution (bottle properly venting).
4. Reconnect electrical connector to back of QuikLYTE® cartridge interface.

Table 2-9. Host Communication

Error code 316—Instrument • Improper communications settings, 318, 321, 323, 484, 485, 486
communication software has not received either instrument or LIS/host
a recognizable “handshake” signal.
Error codes 318 and 323—When a data • Hardware failure, either instrument or
packet is received by LIS/host, it runs LIS/host
parity and checksum verification on the
packet. If parity fails, the LIS/host sends
a NAK signal to the instrument, which
then resends the packet. If checksum
fails, the same will occur and an ENQ
signal is sent to the instrument. The error
message is generated if this occurs four
consecutive times.
Error code 321—The instrument
communication software did not receive a • Cabling/connections or phone line
response from the LIS/host regarding problems
receipt of a data packet.
Error code 317—The LIS or host • Incorrect data format 317
computer attempted to send a data • Poor connection
packet to the instrument and the packet • Electrical noise
was received incorrectly.
Error code 319—Instrument received • LIS/host application software 319
message from LIS/host and could not malfunctioning, not ready, or
identify it. incorrectly set up.
Error code 320—Instrument received 320
acknowledgment but did not receive
accept/reject response from LIS/host
communications software.
Solution
1. Check communications parameters for Xpand™ and LIS/host—they should be the same.
2. Turn mode to OFF, press STORE CHANGES, and wait 30 seconds. Then set the mode to what has been selected for your
instrument and press STORE CHANGES.
3. Check communication path. The cable should be in good condition and firmly connected at each port.
4. Reboot system.
5. The instrument's communication program resides on the hard disk. Reboot the instrument.
6. Print out the poll message on the system printer. From the Operating Menu, press F6: SYS CONFIG, then F7:
PASSWORD. Type “noisy.” The printout data reflects the poll message being sent but is not a hardware check.
7. Make sure host cable is connected to interface port and serial expansion card is fully seated in computer mother board.
8. If the error still occurs, replace the computer.
Error code 322—LIS/host sometimes • LIS/host has run out of storage 322
refuses a result sent to it; it tells the space.
instrument to keep sending result while it
tries to find some room to store it. After
50 unsuccessful tries, this error message
is sent.
Solution
1. Make sure communication between Xpand™ and LIS/host exists.
2. Check LIS/host to see if result storage area is full.

Table 2-10. “Critical Time Missed” or “Block Time Missed”

Critical Time Missed—The time to • Other system problem 328, 329, 332, 333, 334, 335, 336, 337,
automatically reinitialize a module that • Software 338, 421, 467, 468, 469, 470, 523, 548,
had an error has extended into the time 555
reserved for the next test.
Block Time Missed—When a mechanism
is about to be moved by the control
system, the system first checks whether
the scheduled movement start time has
passed. If it has, the mechanism is not
moved, and the error message appears.
This is typically caused when other
process errors result in unanticipated
delays.
Solution
Hex No. Description

F Reset
interchangeable.
Table 2-11. “Failed to Recover After Process Error”

Module failed to properly reinitialize after • Other system problem 401, 402, 403, 404, 554, 557, 575, 589
process error was received. Further
processing is discontinued until the user
resets the system. This prevents the
system from endlessly attempting to
recover from a gross error.
Solution
This error is normally preceded by a specific process error for that module. Check the Error Log and follow the corresponding
troubleshooting procedure for that error.

Table 2-12. “IMT Failed Autocalibration”

An IMT calibration will fail for an • Incorrect fluid level 384
unacceptable slope for one or more • Pinched or obstructed tubing
sensors or for unacceptable Air or Liquid • Fluid not flowing
values. • Time left or number of tests expired
for QuikLYTE® cartridge
• QuikLYTE® cartridge failed
Solution
Using the IMT Calibration screen or the calibration printout, determine which values are unacceptable and then follow the
appropriate steps on the following pages to resolve that problem.
If a sensor (Na+, K+, Cl-)
1. Check that the IMT cartridge interface (tower) is completely closed and that no tubing is being pinched by the tower. Follow
tubing routing through tower using diagram on label (on IMT lid).
2. Check:
• for sufficient volume of Standard A, Standard B, and Flush in the bags
• that the bags are connected to the correct tubing
• that the bag fittings are in the down (toward the tray) position
3. Prime the IMT with Salt Bridge solution and ensure that it is flowing out of the Salt Bridge solution bottle through the R1
tubing.
4. Run an IMT condition cycle:
(OP MENU > F4: SYSTEM PREP > F3: IMT > F4: COND/DILCHK > F1: COND)
5. Clean the IMT system using the screen prompts. Press the HELP key for detailed information on the IMT System Clean
screen. (OP MENU > F4: SYSTEM PREP > F3: IMT > F8: IMT SYS CLEAN)
6. Replace the QuikLYTE® cartridge.
Table 2-13. IMT Sample/Standard Fluid Detect Failure

A typical cause of this error is insufficient • Incorrect fluid level 311, 312
sample in the sample container (311), or • IMT cartridge interface top was open
insufficient fluid in the Standard A or B • Pinched tubing
bag, or there is air in the A and B tubing • Fluid not flowing
because the Standard bag fittings are not • IMT sampler misaligned
in the down (toward the tray) position
(312).
Solution (311)
1. Check for sufficient volume of sample in the sample container and that the sample container is in
the correct position.
2. Check that the IMT cartridge interface (tower) is completely closed and that no tubing is being pinched
by the tower. Follow tubing routing through tower using diagram on label (on IMT lid).
3. Check the X0 tubing (from the IMT Port to the IMT rotary valve for any pinches, clogs, or leaks.
4. With the instrument in Standby, place 3 or 4 drops of water in the IM T Port and verify that the water is not drawn down into
the IMT drain.
5. Prime Flush fluid and watch how the IMT Port drains. If it is draining slowly or not at all, clean or replace
the IMT Port assembly.
(OP MENU > F4: SYSTEM PREP > F3: IMT > F3: ALIGN PRIME > F7: PRIME FLUSH)
6. Check the sample probe alignments to the port, photometric sample drain, and segment. Ultrasonic mix in IMT port is
sensitive to sample probe alignment.
7. Clean the IMT system using screen prompts. Press HELP key for detailed information on IMT System Clean screen.
(OP MENU > F4: SYSTEM PREP > F3: IMT > F8: IMT SYS CLEAN)
8. Replace the IMT cartridge.
Solution (312)
1. Check for sufficient volume of Standard A and Standard B in the Standard bags and that the Standard bag fittings are in
the down (toward the tray) position.
3. Check the A, B, X1, and X2 tubing for any pinches, crimps, or leaks.
4. Run an IMT condition cycle.

Table 2-14. “IMT Fluid Detected When Air Expected”

An air segment that should be ahead of • Improper air segmentation 313, 314
the sample or standard fluid was not • Pinched or obstructed tubing
detected (no air in QuikLYTE® cartridge • IMT pump and sample tubing
when expected). malfunction
Solution (313)
1. Calibrate the IMT and rerun the sample.
3. Check the IMT port for proper operation. (OP MENU > F4: SYSTEM PREP > F3: IMT > F8: IMT SYS CLEAN > F3:
OPEN/CLOSE PORT). While filling the port with water, toggle F3 to ensure the port holds water when closed, then
drains quickly when open.
To remove a clog from the IMT Port:
a. Stylet the IMT Port and then prime with Flush fluid.
b. While priming with Flush fluid, use a transfer pipette to force 100 % bleach into the IMT Port.
Use 2 or 3 applications of bleach into the port in this manner.
c. Prime with Flush fluid to remove any residual bleach.
To remove a clog from the IMT Port solenoid valve:
a. Disconnect the W2 tubing from the bottom of the IMT Port.
b. Connect a syringe filled with water to the W2 tubing.
c. Press the valve open button on the bottom of the IMT Port solenoid valve.
d. Force the water through the W2 tubing and the IMT Port solenoid valve.
e. Reassemble the IMT Port assembly and prime with Flush fluid. If a clog still exists, replace the
IMT Port assembly.
4. Check the X, X0, X1, X2, and X3 tubing for pinches, crimps, and leaks. Replace tubing if necessary.
Clean the IMT system using screen prompts. Press HELP key for detailed information on IMT System Clean screen.
5. Run 2 or 3 IMT condition cycles.
Solution (314)
2. Run an IMT condition cycle.
3. Clean any salt buildups around the IMT cartridge interface and the pogo pin connectors.
4. Check that the Standard A, Standard B, and Flush bags are in the correct positions in the tray and that the bag fittings
are in the down (toward the tray) position.
5. Check the IMT port for proper operation. (OP MENU > F4: SYSTEM PREP > F3: IMT > F8: IMT SYS CLEAN > F3:
OPEN/CLOSE PORT). While filling the port with water, toggle F3 to ensure the port holds water when closed, then
drains quickly when open.

Table 2-15. “Floppy not Ready” Errors

Errors generated when the system is • Bad disk 353, 359, 360, 361, 362, 363, 354, 364,
reading or writing out data files (e.g., Flex 366, 367, 368, 370
inventory). The difference between the • Bad disk drive
read/write files and the long read/write
files is not important in troubleshooting • Floppy disk is write protected
the problem. Every time a data file is read
in or written out, a checksum is • Loose connector
calculated and compared against the
checksum in the file. If the system is • Computer
unable to read the checksum, error
message 363 or 368 is generated.
Solution
1. Make sure that the Dimension® Xpand™ backup floppy disk is seated completely in the disk drive.
Eject and reinsert.
2. If the error continues, exit Xpand™ software to Console Menu and replace backup disk with a new disk.
Restart the Xpand™ application (option 1).
3. If the error continues and has been running six months or more, clean the drive.
4. If the error continues, perform the following steps.
a. Exit Xpand™ software to the Console Menu, then type 99. The / XL prompt appears.
b. Type the following in lower and uppercase letters as they appear below.
touch /instr/config/NOBU
c. Type exit. The instrument software will reload and writing to the floppy will be disabled.
Table 2-16. “Heat Torch Timed Out”

Heat torch temperature control unit did • Leaking air from new cuvette air 261, 419
not begin controlling temperature within valve (750897) tubing connection to
1.6 seconds after heat torch start-up. cuvette form air supply elbow.
The heat torch did not warm up fast • Open heat torch heater element
enough from a cold start to form good • Blown heat torch fuse, 24 “2B” on
cuvettes. fuse “A” board.
• Bad thermocouple—shorted or
detached from diffuser
• Air pressure misadjusted
• Air flow rate misadjusted
• Bad diaphragm
• U-seal or form solenoids misadjusted
or sticking
• Heat torch tubing kinked, plugged,
leaking or disconnected
• Heat torch plugged
• Loose connection
• Cuvette Board
Solution (261)
1. Check that the solenoid arms are locked in place.
2. Check that initial air flow on flow meter during the film softening phase is 5.5 ± 0.5 L/min. (or current specification on PM
checklist). Air pressure reading (in PSI units) during this phase should be a value less than the flowmeter value (in L/min
units). Pressure reading values higher than flowmeter value during softening phase indicates blockage in the heat torch, or
blockage anywhere “downstream” of gauge panel manifold to the heat torch.
a. Check LED CR3B on cuvette board is pulsing in standby, but comes full on at the start of a cuvette formation, then
begins to blink on and off. If CR3B is not on (at all), check fuse 24 2B on fuse “A” board.
3. Reseat connector to form assembly (P13K). Check resistance of heat torch. The resistance between pins 1 and 4 on the
form assembly should be approximately 8 ± 2 ohms. If it is not, replace the heat torch assembly.
a. Be sure to disconnect 24 volts before measuring resistance.
4. If error repeats, reseat the Cuvette Board or replace it.
Solution (419)
1. Hold your finger over a cuvette as it is being formed and see if the air is warm.
2. Under normal operation, the air leaving the heat torch will be hot.
a. If the air is warm and does not ramp up within a few seconds, the heat torch thermocouple is not operating properly and
the heat torch must be replaced.
b. If the air is not warm, the heat torch is not receiving power. Check connectors P/J13K on the heat torch. If connections
are good, check fuse 24 2B on fuse “A” board.

Table 2-17. “Three Bad Cuvettes Sequentially Formed”

When the system is forming cuvettes, • Any “bad cuvette” error 265
and there is an error (such as heat torch
timeout), it will not stop forming cuvettes
just because of one error. But, if the
system detects that the last three times
that it has tried to make a cuvette, a “Bad
Cuvette” error was generated, it will stop
trying to make cuvettes and generate the
above error.
Solution
Check the Error Log for the first “Bad Cuvette” error that appeared. Troubleshoot the minor error associated with this first “Bad
Cuvette” error.
Table 2-18. “Cuvette Film End of Roll Detected”

When checking a newly-formed cuvette, • End of cuvette film roll: end-of-roll 263
the photometer measured out-of-range indicator stripe blocks photometer
absorbance readings (above 2000 mAU) light
for wavelengths 293 through 600. (This • Photometer misaligned to cuvette
check ignores 700.) • Measurement system problems:
photodiode detector or A/D circuit
Solution
NOTE: When this error occurs, it must be cleared by pressing F3: RESET COUNT on the Film Load screen in Diagnostics. If
the cuvette film cartridge is not changed, the cuvette count must be restored using the
F4: RECALL COUNT key on the same screen.
1. Check whether the opaque end-of-roll indicator strip is visible. If so, install a new cuvette film cartridge and update the
cartridge count.
2. If the end-of-roll indicator is not visible, check for something obstructing light from passing through cuvettes.
3. Perform all photometer alignments and calibrations.
NOTE: Photometer alignment procedure must be performed whenever the source lamp is replaced or cuvette wheel is
adjusted.
Table 2-19. “Bad Cuvette QC”

Photometric check (air blank) of three • Dirty windows 262, 508
consecutive cuvettes gave mAUs above • Source lamp weak (old) or misaligned
the specification (specification is 500 • Photometer out of alignment
mAU or below for the 340 - 700 nm • Bad cuvette film
filters, 750 mAU or below for the 293 nm • Bad or dirty optical filter
filter). • Film pulling out
HM methods are flagged immediately • Tape stuck to photodiode aperture or
and not rescheduled unless auto-rerun window
feature is turned on. Some HM methods
need three consecutive cuvettes to pass
QC check. Any one of the three will
cause the error to be posted for that HM
assay.
Solution
1. Perform the cuvette window check procedure and clean any dirty cuvette windows.
2. Check the cuvette manufacturing operation for proper cuvette formation. Check that the film height is correct. Make sure the
film is fully blown into the wheel and doesn't pull out when the cuvette wheel indexes.
3. Perform photometer alignment. Photometer must be aligned whenever the cuvette wheel sensor is adjusted.
4. On new instruments, windows may need repeated cleaning in the first few weeks due to haze on inside surface of windows.
5. Labs closed on weekends may need to schedule automatic cuvette removal feature.

Table 2-20. “Failure Detected When Initializing QC Database”

A problem with the QC database (during • Backup Disk
initialization) was encountered during • Computer
boot-up.
or
The system has detected an error with
the QC database which does not belong
to any of the established error categories.
Solution
1. Press Reset to resume operation.
2. Suspect the backup disk or the computer only if this error or associated database errors are repeated.
3. If the error does not clear, perform a controlled power down and then power up the instrument.
4. The QC database should be checked for accuracy.
Table 2-21. “Could Not Open File”

This error is generated when the system • Bad backup disk 345, 353, 354
could not access the data file when • Problem in computer
it went to go to read or write the file.
This can happen if a disk gets
unseated.
Solution
1. Ensure that the disk is seated completely in the disk drive.
2. Perform a controlled power down, but do not turn off the instrument power.
3. Replace with a new back-up disk.
4. See Table 2-15 “’Floppy not Ready’ Errors” for further troubleshooting.
Table 2-22. “Initial Optical Density Exceeded” Does not apply to Xpand

For each photometric method, specific • Lipemic, cloudy, dirty sample 274, 275
absorbance limits cannot be exceeded at • Dirty windows, optics
the beginning (275) of or end (274) of the • Weak source lamp
reaction. This error appears on the report • Dirty or defective photodiode
slip as an Absorbance error next to the detector
method whose limit was exceeded. The
report slip should not report the error
codes listed, since these are now
method-specific and not “Process Errors.”
Solution
1. Make sure the reagent lid and instrument doors are properly closed and in place.
2. If the problem still exists, dilute the sample and rerun.
Table 2-23.“IMT Consumable Required”

383
Solution
Check IMT Fluids inventory through the IMT Change Fluids screen. Replenish fluids as required.

Table 2-24. Insufficient Vacuum in Waste System

Vacuum switch signal not detected when • Pinched or obstructed tubing 290, 291, 459
required. between gauge/switch and waste
bottle
• Leaking or disconnected tubing
between gauge/switch and drain
• Misadjusted or bad vacuum switch
• Pinched vacuum bottle supply line
• Loose vacuum bottle cap or broken
cap fitting
• Dirty or clogged vacuum pump
muffler
• Vacuum pump worn out or not
running
• Corroded, deteriorated, or missing O-
ring on cap fitting
Solution
1. Go to Water Works screen:
(OP MENU > F7: DIAGNOSTICS > F1: ELECTRO/MECH > F6: WATER WORKS).
2. Check that Vacuum Mode field at the bottom of display is in the Always On mode. If not, use arrow keys to move cursor to
highlight field, then press Return to toggle from Cycle On/Off to Always On mode.
3. If problem remains, press F4: VACUUM ON/OFF from the Water Works menu and observe the following conditions:
• Listen for the vacuum compressor motor to turn on and off each time F4 is pressed
• Green LED on the gauge panel comes on as the vacuum gauge rises above 3 in. hg.
• LED CR5C on the auxiliary board toggles on and off each time F4 is pressed
• LED CR3 on the side panel (relay board) toggles on and off each time F4 is pressed
4. If the vacuum compressor can be heard, but the vacuum gauge does not rise above 3 in. hg, check for leaks listed under
probable causes.
5. If the vacuum compressor cannot be heard, and the gauge does not rise, but LEDs CR5C and CR3 come on, then check
fuse F7 on relay board (side panel). LEDs CR5C and CR3 indicate logic signal only and do not represent fuse status or ac
voltage at the load. Refer to schematic 788886 (relay board). If the fuse is OK, check ac voltage connections per Xpand™
System Diagram 766900 sheet 7, zone 3C.
6. If LED CR5C does not toggle, suspect auxiliary board or backplane connections.
7. If LED CR7 does not toggle, suspect signal connections to ac relay board or the relay board “ACJ1” connector.
8. If the vacuum compressor can be heard and the vacuum gauge rises above 3 in. hg, but the green LED on the gauge panel
does not come on, then replace the vacuum switch (not easily adjustable).
Table 2-25. “Cannot Process HM/IMT Tests If Module Deconfigured”

Software must be configured by the user See solution below. 315
(operator) to run the IMT module.
Solution
The IMT must be configured to run IMT tests. From the Operating Menu, press F6: SYSTEM CONFIG and then F5: IMT ON/OFF
to turn ON (or configure) the IMT system.

Table 2-26. Photometer Cannot Find Alignment Center

Photometer probe alignment occurs in • Thermal chamber interference 280, 281, 282
two stages. • Mispositioning of the cuvette wheel
1. Error Check - Photometer moves to • + 15 V Power problems (may also
the current alignment center of the show "Photometer A to D problem")
window. From that point, it moves (Test points on backplane)
back one step at a time and looks • Photometer filter wheel not rotating
for high absorbance count. If the properly (may also display
photometer does not find the "Photometer A to D problem")
window’s edge, it gives an error • Dirty window
message. The photometer • Source lamp misaligned
continues stepping, looking for the
absorbance to go down.
2. Truncation Centering - The
photometer scans the window and
finds the location with the minimum
mAU (absorbance units) reading. It
then finds the point on either side
of that location where the
absorbance value rises to 15 mAU
above the minimum. The zone
between those two points is called
the truncation zone, and its center
becomes the new alignment
center. (If the photometer is unable
to complete this process, an error
message is generated.) The
alignment center of a cuvette is
where the photometer takes a
reading on that cuvette. One
alignment center applies to all
cuvettes.
3. Using the right and left arrow keys
while in the photometer alignment
screen will move a cursor across
the display and show each
photometer reading’s value. These
should be typical air-blank readings
at the center of the display.
NOTE: When alignment is successful,

the offset number
corresponding to the alignment
center is about -5 to -8, but will
not generate an error based on
these offset values.
Solution
1. Check that reagent lid and all light shields and instrument doors are in place.
2. Check formed cuvettes to see if they were manufactured properly.
3. Check source lamp operation/condition and that filter wheel is spinning.
a. Check the source lamp to see if it is loose or mispositioned in the thermal chamber.
b. Check the photodiode detector connections.
4. Perform the cuvette window check procedure and clean dirty windows.
5. See tables 2-30 and 2-45 in this section for additional help.
6. Press Alt/M for additional help.

Table 2-27. “Photometric QC Readings Not Stable”

Any time the system begins new work, • Filter wheel wobble 415
the photometer reestablishes a baseline • Filter wheel motor
for cuvette QC (air blanks). Five cuvettes • Bad connection on photometer board
are examined for transmittance and the or photodiode assembly
best value is saved for the cuvette QC. • Dirty, delaminated optical filter
While taking the readings for these five
cuvettes, the system reads each cuvette
twice, storing two sets of data (primary
and secondary). The readings, which
should be nearly identical, are compared
to each other. If any deltas fall outside
the expected range, a "Photometer
Measurement Check Failed" error is
posted. This error will prevent any tests
from processing.
Solution
1. Check that the screw has not backed out on the filter wheel
2. Check connections P/J34A and P/J34C to photodiode.
3. Change the filter wheel motor.
Table 2-28. Photometer Mispositioned

Photometer did not mechanically position • Thermal chamber interference 276, 277
itself correctly as verified by the encoder. • Cabling restrictions
If the disagreement between the motor • Belt tension
and encoder is 3 to 7 steps, it is • Motor hardware, such as loose
considered a fine error; if 8 or more, a screws
gross error. • Defective motor/encoder
• Loose connections
• Stiff photometer bearing
• Thermal chamber insulation stuck to
baseplate
• Photodiode and magnetic separation
module interference
Solution
1. Ensure the cuvette thermal chamber is seated correctly with no tubing, conduit, or cable interferences.
2. Go to the Photometer Diagnostics Menu and use the up/down and left/right arrow keys to ensure motor and encoder stay
synchronized for entire range of movement.
3. Ensure home sensor changes state when you leave home. If not, replace home sensor.
4. Cycle photometer in diagnostics and if it generates an error, note position.
5. Lower the thermal chamber and check for:
• Binding on thermal chamber.
• Interference with cabling, wiring, or tubing.
• Loose connections.
• Photodiode detector housing scraping on "D" washer. Pull down on housing while installing it.
• Look for signs of scraped paint and metal.
6. Check photometer belt tension
7. Check for loose set-screw on ring-gear attached to photometer housing.
Table 2-29. “Photometer Readings Overrange”

Photometer perceives insufficient light at • Patient sample grossly out of range 273
one or more wavelengths. • Source lamp defective
NOTE: This can be a normal error
during photometric alignment, in which
case no correction is needed.
Solution
1. Perform a photometer alignment.
2. Perform the a cuvette window check procedure and clean any dirty windows.
3. Check if the cuvette film cartridge is empty.
4. Check that the source lamp is not loose or mispositioned. If the source lamp is seated properly, replace it.
5. Check the photodiode detector wires and the photodiode detector mounting. If they are good, check the photometer lenses.
Also check the photometer measurement detector aperture.
6. Check the filter wheel dual sensor.

Table 2-30. “Photometer Readings Underrange”

Photometer perceives too much light. • Source lamp: misalignment or 272
incorrect installation
• Ambient light leaking into the Cuvette
Thermal Chamber
• Photodiode detector unit defective, or
incorrectly installed on photometer
• Photometer out of optical alignment
• Photometer Board defective
Solution
1. Check that the reagent lid, and instrument doors are in place.
2. Perform all photometer alignments and calibrations.
3. Check that the photodiode detector assembly on the photometer arm is mounted tightly. Check the reference aperture and
cables.
4. Check the U-seal alignment.
Table 2-31. “Photometer Source Lamp Off Detected”

The control system has commanded the • Source lamp inoperable 278
photometer source lamp control circuitry • Connection problem
to light the source lamp. The control • Photometer Board problem
circuitry has responded with a signal that • Fuse 24 1D (source lamp)
indicates the source lamp is not drawing • Fuse 24 1C (filter wheel motor)
any current. Software may automatically
inhibit the source lamp voltage if a filter
wheel problem is detected. But it will still
report this error.
Solution
1. Make sure filter wheel motor is spinning by observing CR3C and CR3D on photometer board for blinking filter wheel home
and position signal. If not spinning, check fuse “A” board 24 1C.
2. Check CR3B on photometer board. If out, check fuse 24 1D on fuse “A” board, which provides source lamp power. If fuse is
OK, replace source lamp.
3. Check connectors P/J72B at the source lamp inside the thermal chamber. Replace PN 750293 if suspect. See Xpand™
System Diagram 766900, sheet 10, zone B6.
Table 2-32. “Printer Off Line”

When the system tells the printer to print, • Loose power cable connections 372
it expects a response back to indicate • Blown fuse 24 1B on fuse “A” board
that the printer completed the line. If this
feedback is not received within 30
seconds, this error is generated, and
some or all of the remaining lines may
not be printed out.
Solution
1. Check fuse 24 1B on fuse “A” board. Replace if needed.
2. Check system printer connections per Xpand™ System Diagram 766900 (sheet 8, zone B1 for power) (sheet 9, zone D3 for
communications).
NOTE: Printer icon is displayed immediately upon detecting an error condition. However, an error message may not be
posted until the printer is invoked by the system and printer’s buffer capacity is full.

Table 2-33. “Faulty Reagent 1 Ultrasonic Mix”

The system enabled the reagent Hard Failure 398
ultrasonics to mix, and did not receive a • Blown fuse
feedback signal from the ultrasonic • Defective transducer
system that the probe was properly • Ultrasonics
energized. • Defective or loose probe
• Broken cables
• Frequency shift
Intermittent Failure
• Loose probe
• Probe out of alignment
• Cuvette film misaligned or improperly
routed
• Cables partially broken or frayed
Solution
1. Check ultrasonic cables/connectors per Xpand™ System Diagram 766900, sheet 14, zone B-2.
2. Check the probe tip and tighten if loose. Check that the probe tip is not bent. If the probe tip is bent or damaged, replace it.
3. Perform the reagent 1 probe alignments. Interference may dampen oscillations (i. e., cuvette film, cartridge wells, drain
walls).
WARNING: Do not touch the probe while it is operating.
4. If the probe will not turn ON, check fuse 24 7A on fuse “B” board. Replace if necessary.
5. While energizing ultrasonics, check enable LED CR1A on Ultrasonics Board. If the LED does not light, suspect the
Ultrasonics Board or the cable connections to backplane board.
If the LED lights, and the probe lock LED does not light in synchronization, plug a known, good ultrasonic probe connector
into the suspected faulty drive circuit using test cable 750651.
NOTE: Prior to energizing any ultrasonics, make certain that the probe under test is in the proper position (sample probe in cup
of water, reagent probe tip in drain with water).
6. If the suspected faulty drive circuit works (>98% lock status, probe lock LED in synchronization with enable LED) with the
good probe under test, suspect the original probe or associated cabling. If the probe does not work, replace the Ultrasonics
Board.
NOTE: You can verify your conclusion by plugging the faulty probe connector into a known, good drive circuit and energizing
that circuit in Diagnostics. Be sure the probe tip is properly positioned in water.
7. Check that contacts did not back out of connector housing and locking tab is not pushed or bent inward (prevents locking of
contact).

Table 2-34. “Faulty Reagent 2 Ultrasonic Mix”

The system enabled the reagent Hard Failure 296
ultrasonics to mix, and did not receive a • Blown fuse
feedback signal from the ultrasonic • Defective transducer
system that the probe was properly • Defective or loose probe
energized. • Broken cables
• Frequency shift
• Ultrasonics Board
• Loose probe
routed
Solution
1. Check ultrasonic cables/connectors per Xpand™ System Diagram 766900, sheet 14, zone A-6.
2. Check the probe tip and tighten if loose. Check that probe tip is not bent. If the probe tip is bent or damaged, replace it.
3. Perform reagent probe alignments. Interference may dampen oscillations (i. e., cuvette film, cartridge wells, drain walls).
4. If the probe will not turn ON, check fuse 24 7A on the fuse “A” board; if OUT, replace.
5. While energizing ultrasonics, check enable LED CR2A on the Ultrasonics Board. If the LED does not light, suspect the
Ultrasonics Board or the connections to the Backplane Board.
NOTE: Prior to energizing any ultrasonics, make certain that the probe under test is in the proper position (sample probe
in cup of water, reagent probe tip in drain with water).
6. If the suspected faulty drive circuit works (>98% lock status, probe lock LED in synchronization with enable LED) with the
good probe under test, suspect the original probe or associated cabling. If the probe does not work, replace the Ultrasonic
Board.
NOTE: Verify your conclusion by plugging the faulty probe connector into a known, good drive circuit and energizing that
circuit in Diagnostics. Be sure the probe tip is properly positioned in water.
NOTE: Minor adjustments may be required when exchanging the probe/drive circuit connectors, particularly if you have
done a sample/reagent cross-check.
7. Check that contacts did not back out of connector housing and locking tab is not pushed or bent inward (prevents locking of
contact).

Table 2-35. “Reagent Carousel Incorrect Transition Count”

Control system moves carousel from one • Reagent cartridge not inserted fully, or 266
position to another by motor steps; improperly inserted
movement is verified by checking • Refrigeration system malfunction causing
encoder count. If the two counts differ by ice buildup in reagent storage
more than 8, the error message is • Interference with reagent carousel motion
displayed. - cartridge labels, lid stock, or other
foreign objects hanging up on tub liner at
NOTE: Reagent Carousel, Reagent Flex® entry or coolant entry openings
Tray, Flex® Tray and Flex® • Reagent tray drive wheel height out of
Wheel all mean the same thing. adjustment
• Motor coupling loose on motor shaft
• Momentary disengagement of urethane
gear and reagent tray drive ring
(skipping)
• Encoder wheel loose on motor shaft
• Encoder disk rubbing on internal mount
Solution
1. Check reagent tray for the following:
a. Binding
b. Interferences (e.g., with reagent tray cover, probe, wires, tubing)
c. Loose hardware
d. Loose connections
e. Ice—If ice is present, it must be thawed by removing the refrigeration solenoid AC fuse on AC fuse panel (left side) for
several minutes. Refer to Thermal System troubleshooting if problem persists.
2. Enter diagnostics and cycle the reagent tray. While the reagent tray is cycling, observe the “steps-encoder” field and verify
the two counts agree with each other (any difference between them will show up in the parenthesis beside). Theoretical
difference should be 0. If the is difference is 0 to 8, no error will be generated. A difference of greater than 8 will be
generate a Reagent Carousel Mispositioned error. Although no error is generated for a difference of 8 or less, you may
want to investigate further. By watching the carousel position status at the same time while cycling, you may be able to
isolate an area of concern.
Table 2-36. “Reagent Lid Open Detected During Initialize or Processing”

No "closed" indication received from • Lid open 292
reagent lid interlock switch. • Loose lid hinge
• Bad switch
• Bad wiring/connections
Solution
1. Close the reagent area lid.
2. Locate LED CR3D on the Auxiliary Board. With the reagent lid down, the LED should be ON. Lift the reagent lid and the
LED should be OFF.
3. If LED CR3D is not operating properly, check connector P/J30D to switch per Xpand™ System Diagram 766900, sheet 19,
zone D-7.
4. Replace the reagent lid switch.
Table 2-37. “Process Error During Preparation”

Some other process error occurred (e.g., ! Some other error code occurred 381
reagent probe lost steps) during reagent simultaneously
preparation.
Solution
This error will zero the inventory for the well just hydrated. The Error Log will show which cartridge was affected. Check the Error
Log for other errors associated with the same method and troubleshoot those errors.

Table 2-38. “Prepared Reagent Failed Quality Assurance”

After a cartridge well was hydrated, or • Dirty windows 382
after reagents were combined/mixed in a • Source lamp weak (old) or misaligned
cartridge, a photometric check was • Photometer out of alignment with cuvette
performed on the dispensed reagent in a • Photometer out of alignment
cuvette, and the result fell outside • Reagent probe out of alignment
allowable limits. • Bad cuvette film
• Improper fluid delivery to cell – pump,
tubing, etc.
• Incomplete mixing – ultrasonics,
loose/worn probe, etc.
• Cartridge problem – no tablet, wrong
tablet, etc.
Solution
This error will zero the inventory for the well just hydrated. The Error Log will show which cartridge was affected. Remove the
affected cartridge from the instrument inventory and inspect it for tablet dissolution, color, and appearance.
1. Perform reagent probe alignments.
2. Check reagent pump tubing for leaks, air bubbles, and tightness.
3. Check the mounting screws on both reagent syringes for tightness. Check the syringes for proper motion, leaks, and air
bubbles.
4. Replace both reagent syringe tips and the diluent filter in the water diluent bottle.
5. Check the reagent probe tip for tightness. Replace if it is worn or bent.
6. Remove and clean the optical filters. Replace if necessary.
7. Check reagent ultrasonics. If the lock status is not within specification, troubleshoot ultrasonics using Table 2-41 (error 296).
8. Run filter data to check mAU threshold.
Table 2-39. Incorrect Sample Cup

These errors are generated when the ! Software 377, 378
sampler control software determines that
the sample cup to be used during a test
is not the one that the “screen” software
requested. There are some checks and
balances in the software to flag
unexpected conditions and not
compromise results, and these error
messages are an example of how these
errors are detected. There is nothing
wrong with the particular instrument that
generated the error, other than the fact
that some sequence of events resulted in
a condition that caused this error.
Solution
1. Go to the error log and look to see if there are any other errors that occurred around the same time.
2. If any error occurred at the same time, troubleshoot that error. If two or more errors occurred at approximately the same
time, troubleshoot the one that occurred first, because it may have caused the others.
3. If no other error occurred at the same time, press Reset. If the error reoccurs, do a controlled power down, and power up
the instrument. If error repeats, suspect a software problem.
Table 2-40. “Sample Lid Open Detected During Initialize or Processing”

®
This error does not apply to Dimension Xpand™

Table 2-41. “Faulty Sample Ultrasonic Mix”

The system enabled the sample Hard Failure 298
ultrasonics to mix, and did not receive a • Defective transducer
feedback signal from the ultrasonic • Worn or damaged probe
system that the probe was properly • Broken cables
energized. • Frequency shift
• Blown fuse
• Ultrasonics Board
• Worn or damaged probe
routed
Solution
1. Check sample arm ultrasonic cable and connections per Xpand™ System Diagram 766900, sheet 21, zones A and B.
2. Check the sample probe tip and tighten if loose. Check that the sample probe is not bent or skewed. If it is, replace it.
3. Perform a sample arm alignment. Interference may dampen oscillations (i.e., cuvette film, drain walls).
4. If the sample probe will not turn ON, check fuse 24 7B on fuse “B” board; if OUT, replace fuse.
5. While energizing ultrasonics, check enable LED CR3A on the Ultrasonic Board. If the LED does not light, suspect the
Ultrasonic Board or the connections to the backplane board.
NOTE: Prior to energizing any ultrasonics, make certain that the probe under test is in the proper position (sample probe
in cup of water, reagent probe tip in drain with water).
6. If the suspected faulty drive circuit works, (>98% lock status, probe lock LED in synchronization with enable LED) with the
good probe under test, suspect the original probe or associated cabling. If the probe does not work, replace the Ultrasonic
Board.
NOTE: You can verify your conclusion by plugging the faulty probe connector into a known, good drive circuit and
energizing that circuit in Diagnostics. Be sure the probe tip is properly positioned in water.
NOTE: Minor adjustments may be required when exchanging the probe/drive circuit connectors, particularly if you have
done a sample/reagent cross-check.
7. See Table 2-33.

Table 2-42. “Reagent Carousel Not on Home When Expected”

The instrument checks for home only if it • Motor coupling loose on motor shaft 122, 124, 125, 126, 267
is using the corresponding cartridge slot, • Home sensor failure (e.g. connector,
when time permits between cartridges, or damage, noise)
at the end of a run. Consequently, • Reagent tray was removed and then
considerable time may pass between replaced in a different position
successive home checks. If home isn’t NOTE: In this case the system restores
where the instrument expected it, all itself, and reagent inventory is not
inventory and method results since the compromised.
last time the instrument was in • Momentary disengagement of urethane
STANDBY are in doubt. gear and reagent tray drive ring
(skipping)
NOTE: Reagent Carousel, Reagent WARNING!: This is a SERIOUS
Wheel, Reagent Tray, and
Flex® Tray are all equivalent ERROR, affecting past and
terms. future chemistry results. DO
NOT clear this error message by
pressing Reset. DO NOT attempt
to run instrument until the cause
of the error is found and
corrected.
Solution
1. Check LED CR2A on the Motor Control Board #2 to verify that reagent tray is at home position. If tray is at home position,
LED CR2A will be ON. If LED is OFF, press Reset and verify tray moves to its home position. If it does not move to home
position, follow [124] “Reagent Carousel Cannot Find Home” error message actions.
2. Verify the reagent cartridge inventory on the instrument by randomly removing reagent cartridges from the instrument.
Ensure that the reagent cartridge selected on the Reagent Cartridge Inventory screen is the same cartridge which was
actually removed from the instrument.
3. Run Quality Control on ALL methods which are in instrument inventory.
4. Verify all 44 slots have correct Flex® inventory:
(OP MENU > F7: DIAGNOSTICS > F1: ELECTRO/MECH; F1: REAGENT; F6: REAGENT TRAY).
This screen defaults to slot 0. Pressing F3: NEXT SLOT will present current Flex® information for slot 1. Each time F3:
NEXT SLOT is pressed, the tray will increment one slot position and display Flex® cartridge information for that slot. Press
F3: NEXT SLOT for all 44 slots, including slot 0, while checking the actual Flex® label against the displayed information.
If a Flex® is present, but no information is displayed (instrument thinks the slot is empty), then discard the Flex®.
If the displayed information is incorrect, then record the information and “remove” from inventory screen by disabling
barcode (do not remove while in diagnostics).
NOTE: A shortcut to a particular slot number is to type in one slot number before the slot to be accessed in the GoTo field and
press Return. This will move the tray to that slot. Now pressing F3: NEXT SLOT will increment one position and display
the information for that slot.
WARNING!: Incorrect reagent inventory will be indicated by incorrect QC results. For those
methods, remove the affected reagent cartridges from instrument inventory and discard.

Table 2-43. Temperature Out of Range

NOTE: Disregard these error messages if instrument has been powered up less than one hour.
NOTE: These errors are not associated with the temperature monitoring circuitry.
A cuvette temperature error condition • Improper temperature setting 264

exists whenever the cuvette temperature • Air, baseplate, or evaporator thermistor
is not being controlled within the or cable
expected duty cycle. The cuvette • Heater circuit open
temperature icon will appear on the • Fuse
status bar on the CRT display. • Water in the tub (Cuvette Hot)
The error message is displayed only if • Cuvette board
the photometer tries to take a reading
when a temperature error condition
exists (i. e., the temperature icon is
present). Otherwise, if no tests are
processing, only the icon will be
displayed. Also, the test result will not be
printed; instead the message "Process
Error" will be printed on the test result
line.
There is an option to override the
temperature error condition. In that case,
the message "Temp Override" will
appear on the status bar.
If the photometer takes a reading when
an overridden cuvette temperature error
exists, the error message in this table’s
title will not occur, and the test result will
be printed; however, the message
"Temperature" will appear next to the
printed result.
Solution
1. Check lab’s ambient temperature (65-85 degrees F.)
2. Check that rear cabinet fan is operating and LED CR3D on cuvette board is pulsing or ON. If not, check AC fuse on left
side panel and replace if necessary.
3. Refer to Thermal System Non-Error Code Troubleshooting.
Table 2-44. “Heat Torch Thermocouple Open”

Thermocouple failed resistance check • Broken/defective wires or connector 371
by cuvette control system • Thermocouple open
• Thermocouple unplugged
Solution
1. Check connectors P/J13K to the heat torch assembly and 2J1 A9 and C9 between the cuvette board and backplane.
Measure the resistance between pins 2 and 3 on the cuvette heat torch assembly. The resistance should be 0.5 ohms. If
the reading is higher than 0.5 ohms, replace the heat torch assembly. Refer to Xpand™ System Diagram 766900, sheet
11, zone C-6.
2. If the error does not clear, replace the cuvette heat torch assembly.
3. If the error still does not clear, perform a controlled power down, reseat the cuvette board, and power up the instrument.
4. Replace the cuvette board if all other measures fail.

Table 2-45. “Photometer A to D Problem”

The system is not sensing an interrupt • Filter wheel is not spinning 271
signal from the photometer A/D • Filter wheel sensors defective,
circuitry. Normally this error is triggered disconnected or loose
off the filter wheel home and position • Photodiode cable to Photometer Board
sensors. broken, disconnected or loose
• +15 volt problem (test points on
backplane)
Solution
1. Check fuse 24 1C on fuse Board “A”. Replace fuse if LED is out.
2. Check LEDs CR3D and CR3C on the Photometer Board and verify that they are blinking. If not, go to step 3. If blinking, go
to step 4.
3. Remove R2 reagent arm and observe that filter wheel is spinning. Then go to photometer diagnostics, (F4) system
diagnostics to test filter wheel motor. If filter wheel home and position fields on diagnostic screen do not show activity while
filter wheel is spinning, then replace photometer dual sensor.
4. Perform all photometer system alignments and calibrations.
5. If problem persists check connector P/J34C on the side of the photometer assembly inside the thermal chamber. If signs of
wear, replace with cable PN750915 and 750293. See Xpand™ System Diagram 766900, sheet 10, zone D6.
Table 2-46. “Waste Sensor Active”

Waste bottle level indicator indicates • Waste bottle full 300
when waste bottle is full. • Float switch
• Auxiliary board
Solution
Steps 1 and 2 used for “Unplumbed” or “Manual” mode only.
1. Do not press Reset. Allow the instrument to complete the work currently in progress. There is enough space in the waste
bottle to complete the work already processing.
2. When the instrument returns to STANDBY status, empty the chemistry waste bottle, and press Reset to clear the error
message and begin processing Steps 3 and 4 used for “Plumbed” and “Unplumbed” mode.
3 If the error does not clear, unplug connector J30A and short the two pins with a paper clip while observing CR2B on
auxiliary board. If LED does not change state, suspect the auxiliary board.
4. If CR2B changes while shorting and unshorting J30A, suspect the waste bottle cap/sensor assembly.
Table 2-47. “Hi and Low Water Sensors Simultaneously Active”

All three sensors on the water bottle are • Water bottle cap/sensor assembly is 399
in conditions that indicate the connector unplugged
is unplugged.
Solution
Plug in P/J1A.
Table 2-48. “Timeout Occurred Before High Water Sensor Active”

"Water bottle low" sensor directed water • Sensor Failure 400
bottle to fill but the "Filled" sensor did • Fuse 24 6B
not activate within 2 hours. • Water Inlet Valve
• External Water Supply
• Auxiliary Board
Solution
1 Remove the bottle cap and go to the Water Works Diagnostic screen. Lift the second float from the bottom and see if the
"water bottle filled" sensor changes state can also be observed at LED CR2D on auxiliary board. If it does, suspect the
water inlet valve, the external water supply, or the auxiliary board.
2. Press the manual override button on the water inlet valve and check to see if water flows to the bottle. If it does, check fuse
24 6B on fuse “B” board. Replace fuse if needed.
3. If fuse is OK, turn on water inlet valve in Water Works diagnostic screen and listen for valve to click on and off when
toggled. IF no valve activity, replace auxiliary board. Refer to Xpand™ System Diagram 766900, sheet 19, zone 2C.

Table 2-49. “Low Water Sensor Active”

Water low sensor did not change state • Sensor Failure 301
after 1 minute of filling time. • Water Inlet Valve
• External Water Supply
• Auxiliary Board
• Connector and cabling
Solution
1. If water bottle is empty, push in the manual override button on the back of the inlet valve. If water flows, then check fuse 24
6B on fuse “B” board. Replace fuse if needed.
2. If fuse is OK in step 1 above, go to Water Works diagnostics screen and toggle the water inlet valve on and off while listen
for clicking sound. If no valve activity, suspect auxiliary board.
3. Check cable and connections per Xpand™ System Diagram 766900, sheet 16, zone 4C. 24 volts dc should be present on
both pins in de-energized state. Toggling the solenoid ON pulls the control line close to 0 volts.
4. If the water bottle is not empty, suspect the low water sensor or its associated connector and cabling. Replace the water
bottle cap if necessary.
Table 2-50. “IMT Rotary Valve Sensor Problem or Valve Did Not Move”
The control system did not detect ! Rotary valve sensor problem 542
movement of the IMT rotary valve. ! Rotary valve sensor PCB
Solution
1. Press Reset. If the message reappears, continue with step 2.
2. The fuse for the IMT rotary valve may have blown. Its fuse LED indicator, 24-5B on Fuse Board B in the card cage area,
should be lit. If it isn't lit, replace the fuse with a like fuse from the Accessory Spare Parts Kit.
3. Check the operation of the IMT rotary valve motor and sensor. To do this:
a. Go to the IMT Diagnostics screen.
(OP MENU > F7: DIAGNOSTICS > F1: ELECTRO/MECH > F3: IMT)
b. Move the cursor to the IMT Rotary Valve line in the Motor portion of this screen, and then press
F2: TEST MTR ONLY. Check CR3C (Home) and CR3D (Pos) on motor control board #3 for LED activity.
c. If the IMT Rotary Valve Connection field indicates FAIL, the IMT Rotary valve motor could be defective.
d. If the IMT Rotary Valve Home field indicates FAIL, or the numbers at the bottom of the screen are not within ±1,
replace the IMT Rotary valve home sensor, but first check if the sensor connector, P/J184, is loose or unplugged.
Refer to Xpand™ System Diagram 766900, sheet 21, zone A.
4. Check rotary valve sensor board (766780) under baseplate for fluid spills or loose connections. Replace if necessary.
Table 2-51. “IMT Rotary Valve Lost Steps (mfh) or (mth)”

The IMT rotary Valve did not move the ! Defective Motor 543, 544
proper distance. ! Worn rotary valve seal
Solution
1 Press Reset. If the message reappears, continue with step 2.
2. Replace the IMT Rotary Valve seal.
a. Go to the IMT Diagnostics screen:
d. If the IMT Rotary Valve Home field indicates FAIL, or the numbers at the bottom of the screen are not within ±1,
replace the IMT Rotary valve home sensor, but first check if the sensor connector, P/J184, is loose or unplugged.
5. See Xpand™ System Diagram 766900, sheet 17, zone A for electrical connection.

Table 2-52. “IMT Rotary Valve Sensor Did Not Turn On or Valve Did Not Move”
The control system did not detect ! Rotary valve sensor problem 540
movement of the IMT rotary valve. ! Rotary valve sensor PCB
Solution
2. The fuse for the IMT rotary valve may have blown. Its fuse LED indicator, 24-5B on Fuse Board B in the card cage area,
should be lit. If it isn’t lit, replace the fuse with a like fuse from the Accessory Spare Parts Kit.
a. Go to the IMT Diagnostics screen.
d. If the IMT Rotary Valve Home field indicates FAIL, replace the IMT rotary valve home sensor, but first check if the
sensor connector, P/J184, is loose or unplugged.
5. See Xpand™ System Diagram 766900, sheet 17, zone A for electrical connection.
Table 2-53. “IMT Rotary Valve Illegal Error Code”

The control system did not recognize 541
the error code.
Solution
2. Go to the Error Log screen
(OP MENU > F7: DIAGNOSTICS > F6: ERROR LOG)
3. Troubleshoot any error code(s) that occurred at the exact same time or the error code immediately below this error code.
For example:
IMT Rotary valve illegal error code [433] Mon Apr 21 11:00
"Troubleshoot this error" [xxx] Mon Apr 21 11:00
For help with troubleshooting the [xxx] error code:
Move the cursor to the [xxx] error code line and then press F5: MORE INFO (or the Alt-M key combination).

Table 2-54. “IMT Failed to Detect Flush Fluid”

Air/Fluid detect sensor in IMT cartridge ! No flush solution in bag 545
did not detect liquid flush solution. ! Restricted flow
! Rotary valve seal
Solution
1. Check for sufficient volume of Flush fluid in its bag and that the bag fitting is in the down position (toward the tray).
Replace the bag, if necessary.
2. Verify that the Flush fluid can be primed. To do this:
a. Go to the Align/Prime screen.
(OP MENU > F4: SYSTEM PREP > F3: IMT > F3: ALIGN PRIME)
b. Press F7: PRIME FLUSH. You should see Flush fluid being pumped into the IMT port.
3. Check that the following tubing connections are tight and that there are no pinches, crimps, leaks, or obstructions in the
tubing:
• F1: from the Flush bag to the Flush pump
• F2: from the Flush pump to the IMT Port
• X0: from the IMT Port to the IMT rotary valve
• X1: from the IMT rotary valve to the QuikLYTE® cartridge.
Replace tubing as necessary.
Check that the flush pump is operating properly:

a. Go to the IMT Advanced Diagnostic screen.
(OP MENU > F7: DIAGNOSTICS > F1: ELECTRO/MECH > F3: IMT > F8: ADVANCED DIAG)
b. Move the cursor to the Flush field and press the Enter key twice. If the pump is operating, you should hear the pump
‘click’ on and off and see Flush fluid being pumped into the IMT Port. If this does not occur, replace the Flush pump.
Check that the flush pump is dispensing the proper amount of Flush fluid:
Refer to the table below for how much Flush fluid should appear in the IMT port. If the Flush pump is not dispensing the
proper volume of fluid, replace it.
Press Enter Key Proper Fluid Level in IMT Port

4 times 1/3 FULL
8 times 2/3 FULL
16 times Full to the top of the IMT Port
Table 2-55. “Insufficient/Excess IMT Diluent in Port”

The amount of Diluent in the IMT Port ! Crimped D1 and D2 tubings 546, 672
was not sufficient for performing the ! Defective solenoid valves
sample dilution. ! Clogged port fitting
! Faulty sampler level sense circuit
Solution
1. Check for sufficient volume of Diluent fluid in its bottle. Replace if necessary.
2. Check that the following tubing connections are tight and that there are no pinches, crimps, leaks, or obstructions in the
following tubing:
• D1: from the Diluent bottle to the Diluent pump and solenoid valve
• D2: from the Diluent pump and solenoid valve to the IMT port
Replace the tubing if necessary.
3. Check the Diluent pump operation. To do this,
(OP MENU > F4: SYSTEM PREP > F3: IMT > F3: ALIGN/PRIME > F8: PRIME DILUENT)
Observe diluent flow to the IMT port.

Table 2-56. “Auto Align Failed to Sense Std A Alignment Fluid”

Air/liquid sensor in the IMT cartridge did ! No standard A in bag. 547
not detect standard A during a pump ! Restricted flow
auto-alignment. Error is posted after ! Rotary valve seal clogged
alignment cycle completes, not when
first detected.
Solution
1. Check that the IMT cartridge interface (tower) is completely closed and that no tubing is being pinched by the tower.
2. Check:
– for sufficient volume of Standard A, Standard B, and Flush in the bags
– that the bags are connected to the correct tubing
– that the bag fittings are in the down (toward the tray) position
3. Prime with Salt Bridge solution. Verify that it is flowing through the R1 tubing and into the X2 tubing.
(OP MENU > F4: SYSTEM PREP > F3: IMT > F3: ALIGN PRIME > F1: PRIME SALT)
4. Check the R1 tubing inside the Salt Bridge pinch valve for crimps. Reposition this tubing to change where the valve pinches
it, or replace the tubing if necessary.
5. Check that the pressure foot bar on the IMT pump is completely engaged and that the IMT pump rollers are rotating freely.
If a roller seems to be binding or not rolling smoothly, put one drop of Tufoil® on the roller and manually work the roller back
and forth with your hand to lubricate the pump roller.
6. Check the A, B, X1, X2, and X3 tubing for any pinches, crimps, or leaks. Replace tubing if necessary.
7. Check the IMT rotary valve for leaks and that the IMT rotary valve tubing connector is properly seated. If necessary, replace
the IMT rotary valve seal.
8. Clean any salt buildups around the X1 and X2 tubing connections to the IMT cartridge interface and around the pogo pin
connectors. Open the IMT tower and clean any salt from this side of the cartridge interface connections.
9. Replace the X tubing in the IMT pump.
10. Replace the QuikLYTE® cartridge.
Table 2-57. “Cuvette Air Pressure Too High”

During cuvette manufacturing, the control • Miswired pressure switch. White wire 258
system monitors the status of the connected to N.C. instead of N.O.
pressure switch. In the first phase (the connection.
Surlyn® softening phase), the pressure • Diaphragm installed upside down.
should not be high enough to trip the • Pinched tube between pressure switch
switch. If the switch is on, an error and heat torch
message is sent. • Misadjusted air flow – too high
• Bad or misadjusted pressure switch
• Plugged/obstructed heat torch
• Diaphragm installed incorrectly
Solution
1. Look for pinched or plugged lines between pressure gauge/pressure switch and cuvette formation assembly, or blocked
heat torch. Make sure the diaphragm is installed correctly (not upside down).
2. If the green LED next to the air pressure gauge is lit when no air is flowing, check 2 connections to N.O. (Normally Open)
and COM (common) per zone D-5 on sheet 11 of Xpand™ System Diagram 766900.
3. If pressure switch is wired correctly but LED remains ON, replace switch.
4. Check cuvette air valve (750897) connections per zone B-6 on sheet 11 of Xpand™ System Diagram 766900.

Table 2-58. “Cuvette Air Pressure Too Low”

During cuvette manufacturing, the control ! Air leaks at new cuvette air valve 259
system monitors the pressure switch connection to cuvette form air supply
signal during cuvette blowing phase elbow
(form solenoid hard-close). During this ! Cuvette solenoid arm not installed
phase, the switch must activate; securely
otherwise, an error signal is sent. ! Bad or misadjusted pressure switch
! Work, leaky, missing, or improperly-
installed cuvette form diaphragm
! Leaky or loose tubing between pressure
gauge and heat torch
! U-seal solenoid not pushing cuvette arm
firmly enough (solenoid out of adjustment
or sticking)
! Cuvette form solenoid not pushing
plunger firmly enough (solenoid out of
adjustment or sticking)
! Cuvette ring misaligned so that plunger
does not seat at top of cuvette
Solution
NOTE: Before beginning the following procedure, check whether the solenoid arms are loose or mispositioned.
If so, reposition and tighten, then press Reset and watch for the error message.
1. Replace the cuvette diaphragm.

2. Have the instrument make a cuvette. While the form solenoid is energized, verify that:
a. The air flow reading on the flowmeter ball drops to zero. If not, check for leaks.
b. The pressure gauge reading is greater than 15 psi during cuvette formation and its LED (located above the
gauge) is lit when the cuvette plunger is forward. Pressure gauge should hold steady at 20 psi. If not, adjust
pressure regulator.
c. Pressure switch should activate LED at 15 psi (while rising). If not, adjust Allen screw on front of pressure switch
with air compressor on while pushing in the form plunger.
d. When new cuvette air valve is installed, pressure is held until top seal solenoid is de-energized at end of cuvette
cycle.
e. Check electrical connections to cuvette air valve (750897) per Xpand™ System Diagram 766900, sheet 11,
zone B-6.
Table 2-59. “Cuvette Not Sealed”

U-seal microswitch signal not received • U-seal element failure 260
by control system, or U-seal element • U-seal interlock switch not activated—
failure resulting in "U-seal good detect" most likely due to U-seal solenoid out of
signal not being seen by control system. adjustment
Solution
1. Check that cuvette manufacturing solenoid arm is locked in place.
2. Check that the resistance of the U-seal element is between 8 and 12 ohms. If it is not, replace the U-seal element.
3. Check that the microswitch makes contact with the right film guide bracket. Check the microswitch (interlock) with an
ohmmeter. (Disconnect 24 volt connections before checking resistance). See zone B-6 of sheet 11 of Xpand™ System
Diagram 766900.

Table 2-60. “Cuvette Wheel Cannot Find Position”

Control system did not • Cuvette film not routed properly—caught around drive 061, 062, 257
see a cuvette wheel capstan
position sensor • Capstan slipping—loose screws holding nip roll lever spring
transition when on nip roll arm
expected. • Loose drive capstan set screw
• Film drive motor—not running or insufficient torque
• Cuvette window not pushed down all the way—rubbing
against baseplate
• Cuvette film slipped out of film guides—caught on something
• Home hole plug fell out of ring and jammed in ring
somewhere
• Extremely dirty window—sensor can’t see through
• Bad sensor
• Cuvette wheel binding or jammed—foam weather-strip on
thermal chamber, main bearing, etc.
• Solenoid jammed in actuated position
• Film cartridge hang-up or jam—“telescoping” of film roll
inside cartridge
• Film cartridge tension set too high
• Thermal chamber latched too tight
• Temperature probe or alignment gauge pin left in cuvette
hole
Solution
1. Check the cuvette film; look for film jams and/or binding. Check that the idler roller is pressed firmly against the drive
capstan and the bottom edge of the film is between the roller gears.
2. Index the film in diagnostics and observe that the film drive motor shaft and capstan drive move. If no movement, then go
to step 3. Otherwise, go to step 4.
3. Check fuse LED on Fuse “A” board; if OUT, replace fuse.
4. Make sure the cuvette wheel moves as cuvettes are formed.
If the wheel moves, check LED CR2C on the Cuvette Board. If the LED changes state, check the film and wheel for binding.
IF the LED does not change state, replace the cuvette wheel home sensor.
Table 2-61. “System Printer Power Is Off”

System printer lost communications with ! Interface board lock-up 473
computer. Usually accompanied by a ! Blown fuse 24 2B on fuse “A” board.
printer icon with Off displayed within.
NOTE: Xpand™ system printer has

no power switch and no visible
LEDs.
Solution
Check connection to printer interface board from computer’s serial port expansion card and the backplane board. Refer to
Xpand™ System Diagram 766900, sheet 9, zone D-3, and sheet 8, zone B-2.
NOTE: Printer icon is displayed immediately upon detecting an error condition. However, an error message may not be posted
until the printer is invoked by the system and printer’s buffer capacity is full.
If printer system appears “locked up” customers will have to perform a controlled power down, cycle the main power switch, then
reboot the instrument. Service may perform the following steps:
1. Go into Diagnostics, Electro/Mech, Power System, and press F1: TURN 24V OFF.
2. While keeping 24v DC turned off (do not leave this diagnostic screen), remove the left side panel and temporarily
disconnect P12 from the backplane board. P12 is the 6-position AMP Mini Mate-N-Lok connector in the middle of the
bottom row of connectors on the backplane board, just to the left of terminals E1-E2.
3. Once P12 is reconnected, press F1: TURN 24V ON.
4. Press Exit twice, then go into F3: ALIGNMENTS, and attempt to print the alignment file.
5. If problem persists, power down and reboot the instrument.

Table 2-62. “System Printer Paper Is Empty”

System printer detects paper not ! No paper 474
present. Usually accompanied by a
printer icon with Out displayed within.
NOTE: Xpand™ system printer has

LEDs.
Solution
Replace paper roll.
NOTE: Printer icon is displayed immediately upon detecting an error condition. However, an error message may not be
posted until the printer is invoked by the system and printer’s buffer capacity is full.
3. Once P12 is reconnected, press F1: TURN 24v ON.
4. Press EXIT twice, then go into F3: ALIGNMENTS, and attempt to print the alignment file.
Table 2-63. “System Printer Error Light Is On”

System detects an error condition on the 475
System Printer.
NOTE: Xpand™ system printer does

not have an error light. It has
LEDs.
Usually caused by platen lever being left

up. Generally accompanied by printer
icon with ERR displayed within.
Solution
Close platen lever (down).
NOTE: Printer icon is displayed immediately upon detecting an error condition. However, an error message may not be posted
until the printer is invoked by the system and printer’s buffer capacity is full.
3. Once P12 is reconnected, press F1: TURN 24v ON.
4. Press EXIT twice, then go into F3: ALIGNMENTS, and attempt to print the alignment file.
Table 2-64. [component] “Stuck” or “Cannot Find Home”

See Solution Tables 2-2 and 2-3.

Table 2-65. “[component] Probe Cleaner Not Detected During System Check”
During system check, the system reads a • probe cleaner pump needs priming 568, 569
cuvette containing a small amount of • probe cleaner bottle is empty
reagent or sample probe cleaner to • probe cleaner fluid lines are blocked or
indicate if enough cleaner solution is broken
present at the drain. • probe cleaner drain is leaking
Before troubleshooting this error, make • probe cleaner solution is not correct
sure all other system check results are
OK.
Solution
Troubleshoot the probable causes listed.
Table 2-66. “Vessel Present Timeout”

This error does not apply to Dimension® Xpand™
Table 2-67. “Vessel Shuttle Guide Stuck”

The vessel shuttle guide moves reaction • Obstruction – guide may be hitting a 577, 578
vessels between the HM wash wheel, vessel when moving up or down
incubate wheel, and vessel load/unload • guide is sticking or not working smoothly
track. When the guide is activated, its • improper vessel transfer alignments
position (up/down) is verified with an • solenoid or sensor electrical problem
optical sensor.
Error 577 indicates the guide is stuck in
the up position.
Error 578 indicates the guide is stuck in
the down position.
Solution
1. Go to HM diagnostic screen.
(OP MENU > F7: DIAGNOSTICS > F1: ELECTRO/MECH > F2: SAMPLE SYSTEM > F5: HM MODULE)
2. Use down arrow key to move cursor to “shuttle:” field, then press Enter key to toggle the solenoid ON and OFF.
3. If solenoid is activating properly, then perform all “VESSEL TRANSFER SHUTTLE ALIGNMENTS.”
4. Check connections per Xpand™ System Diagram 766900, zone C-2.
5. Replace shuttle guide (730412).
Table 2-68. “Check reaction vessel waste – Reset counter”

The HM module unloads used reaction ! Vessel count > 250 581
vessels into the vessel waste container,
tracking the number as they are
unloaded. When the count reaches 250,
the waste container must be emptied and
the counter reset before unloading can
continue.
Solution
1. Display the HM Counters screen:
(OP MENU > F4: SYSTEM PREP > F6: SYSTEM COUNTERS > F6: HM COUNTERS)
2. Ensure that the waste has been emptied and reset the counter.

Table 2-69. “Incubate wheel temperature out of range”

The HM module incubate ring • HM thermal sensor disconnected, not 582
temperature is outside the range 42°C to installed properly or damaged
44°C. • HM incubate heater is disconnected or
not working
• Blown fuse 24 6B
Solution
1. Check the incubate temperature using the temperature probe.
2. Calibrate the HM temperature using the Temp Monitor screen under the System Prep menu.
Table 2-70. “Vessel mixer – No revolutions detected”

Sensor for vessel mixer 1 [583] or vessel • Mixer sticking – not moving up and down 583, 584
mixer 2 [584] did not activate properly. smoothly
• mixer not rotating properly
• electrical problem
• connector problem (connectors reversed)
Solution
1. Align mix sensor circuit board to be perfectly centered and perpendicular to both mixers.
Table 2-71. “Vessel Aspirator – Possible Obstruction”

W1 wash probe [586] or W2 wash probe • clogged probe or tubing 586, 588
[588] not aspirating properly. • pressure sensor not connected properly
• pressure sensor not operating properly
Solution
1. Temporarily remove the probe from the wash station housing and place in an empty test tube.
2. Display the Pump Prime screen and select HM Wash Pump to prime the wash pump.
3. Observe the fluid in the test tube. If the probe is operating properly, the fluid should fill the tube, then empty it as the
aspirator turns on. If the fluid does not empty, the probe is likely clogged. Replace or clean the probe and repeat the test.
4. If the fluid empties normally, check the pressure sensor.
NOTE: The W1 and W2 probes are identical and can be swapped. If one of the probes indicates a problem, try swapping
with the other probe.
Table 2-72. Bottle Empty

Low reagent/sample/wash sensor is • Bottle is empty 566, 567, 570
activated.
Solution
Replace the empty bottle. If bottle is not empty, troubleshoot the float sensor.

Table 2-73. HM System Not Ready

Incubate wheel is not at the expected • Another process prevented the wheel 561, 562, 563
position for processing. from properly positioning in time
This is typically caused when other • Error recovery failed
process errors result in unanticipated
delays.
Solution
1. Press Reset and check the Error Log for an error that occurred at the same time this error occurred. Troubleshoot this
associated error.
Hex No. Description

F Reset
interchangeable.
Table 2-74. 24 Volts Not Functional

On Xpand™ this error is generated if the • Software configured for an RMS when 443
software is mistakenly configured for an you can’t have one
RMS unit on boot up. The system will try
to turn on a 24 volt supply in the non-
existent RMS.
Solution
1. Power down and reboot configured as Xpand™.
2. Check P/J 92 to DC power supply (24v DC inhibit signal from AUX board via backplane).

Table 2-75. Segment or Sample Aborted by User

All these errors are the result of the • Operator moved or changed item listed in 502
software detecting something has moved minor error code. 503
or changed since processing was 504
started. 505
506
[502] Processing segment has been 538
replaced by a new segment.
[503] Bar code tube on processing

segment has been replaced
[504] Processing segment has been

moved.
[505] Processing segment has been

removed.
[506] Processing bar coded tube has

been moved.
[538] User aborted a sample.
Solution
Have operator correct item indicated in minor error code and restart.
Press Alt/S and restart all samples of aborted segment that were not completed. Press Help for more information on Segment
Status (Alt/S) Screen.
Table 2-76. Communication Problem

The computer buss is locked up. • Defective I/O Board 513
• Defective Computer 514
• Defective Backplane.
Solution
Hex No. Description

F Reset
interchangeable.

Table 2-77. Error in Setting Up Bar Coded Tube Sample

There is a problem as noted by the minor • Host off line 484
error code when reading the bar coded • Instrument to host connections 485
sample tube. • Instrument software setup 486
487
[484] The host computer is not • Host is busy or hung. 488
responding to queries. 489
490
• Too many old samples in memory. 491
[485] Host computer is busy and unable 492
to respond. 493
[486] The instrument has too many • Too many old results in memory must
samples in memory and must wait for send them to host before accepting more
some to be removed before accepting samples. Perform a controlled power
any more. down and restart application software.
[487] The instrument has too many • Make sure host has sample information.
result in memory and must wait some to
be report before accepting any more. • Sample number not in host information.
[488] The host did not find sample ID.

• Sample fluid type not enter in host.
[489] The host did not have the sample

number. • Test methods not specified in host
information
[490] The host did not have the sample
fluid type. • Host is having problems.
[491] No test methods type specified for

sample. • Operator error in placement of tubes
[492] An unknown error code was

received from the host.
[493] A bar coded tube was found at a

position already assigned.
Solution [494]
Correct situation that was determined by minor error code. Refer to Section 2 of Xpand™ Operator’s Guide.
Refer to Table 2-9 “Host Communication” for troubleshooting Host/LIS problems.
Table 2-78. External Printer Off Line

The external printer is not responding. • Printer Off Line 422
• Printer turned off
• Printer disconnected
• Software setups incorrect.
Solution
1. Check that external printer is on and in the “on-line” mode.
2. Check connections between printer and instrument.
3. Check Communications Mode:
(OP MENU > F6: SYSTEM CONFIG > F6: SELECT PRINTER > F2: EXT PRINTER)
4. Store Changes.

Table 2-79. Incubation Wheel Lost While Processing

The software is keeping track of wheel • Loose drive gear on motor shaft 550
position via encoder and it expected to
see home at particular position and did
not
Solution
1. Lift instrument lid then remove two screws that hold drive cover to baseplate.
2. Ensure motor drive gear is fastened to shaft.
Table 2-80. Incubation Wheel Mispositioned

The software told motor to go a number • Alignments 549
of steps but the encoder feedback said • Binding or interference
mechanically it did not go that number of • Loose drive hardware or belt
steps • Defective Encoder
• Defective motor control board.
Solution
1. Perform R2 to incubate wheel alignment and Sample Probe to incubate wheel per Operators guide.
2. Enter Diagnostics:
(OP MENU > F7: DIAGNOSTICS > F1: ELECTROMECHANICAL > F2: SAMPLE SYSTEM > F5: HM >
F8: CYCLE)
3. Observe the Wheel for smooth operation.
4. Check PC Board/Fuse Label to determine which motor control board controls the HM incubate wheel.
5. Then, swap Motor Control Board with another motor control board. If problem moves, order and replace original board.
6. Replace motor/encoder.
Table 2-81. Insufficient Diluent for Autodilution

Table 2-82. Insufficient Sample

Each tube is level sensed at the • Not enough sample in the tube. 389
beginning of the run looking for enough • Defective level sense board 766960. 390
sample to run all the test requested plus • Defective Probe 472
some safety margin. • Defective Cable 766916
• Incorrect Alignments
[389] The level sense determined that • Wrong sample container for assigned
there was some sample but not segment
enough sample to run the
requested tests.
[390] The level sense did not see any

sample within reach of the probe
travel.
[472] The level sense determined that

there was some sample but not
enough sample to run the
requested tests.
Solution
1. Check for sample within tube/tubes in question
2. Check all container alignments.
3. Check connections from probe to level sense board.
4. Replace level sense board PN 766960
5. Replace Transducer PN 766229
6. Replace cables PN 766916
7. Check sampler grounding

Table 2-83. Level Sense Error

The level sense fired outside the normal • Defective level sense board 766960. 389, 390, 472, 750
window that it should see sample. • Loose or defective probe
(High Flyer) • Defective Cable 766916
• Incorrect Alignments
• Wrong sample container for assigned
segment
Solution
1. Check connections from probe to level sense board.
2. Check alignments for all container types.
3. Replace level sense board PN 766960.
4. Replace transducer PN 766229.
5. Replace cables PN 766916.
6. Check sampler grounding.
Table 2-84. Photometer Cannot Access Cuvette

This is a programming error where the • Programming 476
software try to read a cuvette in position
the photometer cannot reach. This
should never occur on released software
Solution
Notify service technical support.
Table 2-85. Photometer Outer/Inner Detector Error

The photodiode has an inner an outer 478
detector. You should see at least a 30 479
mAU difference when you turn the outer
detector off.
[478] There was no difference so the • Defective Photodiode

outer detector is not turning off. • Defective Photometer Board
• Defective cable
[479] The delta is not enough. • Source lamp improperly installed

• Photodiode improperly installed.
• Defective photodiode
• Defective photometer board.
Solution
1. Lower thermal chamber and check that both source lamp and photodiode are installed properly.
Caution: Source lamp is hot
2. Replace Photodiode
3. Replace Photometer Board
Table 2-86. Photometer Unable to Initialize

Photometer did not find calibration or • A new photometer, cuvette, aux, or motor control 477
offset values for the noted items. board was just installed 480
481
• [477] Photometer needs dark current calibration 482
• [480] Photometer needs source lamp calibration
• [481] Photometer needs mau offset calibration
• [482] Photometer needs dark and lamp and mau
offset calibration.
Solution
Correct situation that was determined by minor error code. Perform all photometer alignments in section 4 (Aligning) of Xpand™
Operator’s Guide.

Table 2-87. Required Segment Not in Position

These are errors generated to catch • Programming 464
programming errors. You should not see 465
these errors on released software. 466
Solution
Notify service technical support.
Table 2-88. Sample Arm Mispositioned

The software told motor to move a • Binding or interference 441
number of steps but the encoder • Alignments 442
feedback said mechanically it did not • Loose drive hardware or belt
move the proper number of steps • Defective Encoder
Solution
1. Perform Sample Arm alignments per Xpand™ Operator’s Guide.
2. Test arm in diagnostics observing for binding and insuring motor steps matches encoder steps.
3. Replace sample arm.
4. Replace motor control board #3.
Table 2-89. Sample Probe Mispositioned

of steps but the encoder feedback said • Binding or interference 574
Solution
1. Perform Sample Probe alignments per section 4 (Aligning) of Xpand™ Operator’s Guide.
2. Enter Diagnostics.
(OP MENU > F7: DIAGNOSTICS > F1: ELECTROMECHANICAL > F2: SAMPLE SYSTEM >
F2: SAMPLER > F8: CYCLE)
3. Observe the Sample Probe for smooth operation.
4. Swap Motor Control Board # 3 with another motor control board. If problem moves order and replace original board.
5. Check for short service loop in cables under baseplate. Best to observe from rear panel opening.
Table 2-90. Segment Aborted Press Alt/M

Probable Causes Error Codes
User aborted a segment. • User aborted a segment 339
Solution
Press Alt/M and follow on screen instructions.

Table 2-91. Unable to Establish Cuvette Limits

The photometer checks each newly • Photometer arm out of alignment 284
formed cuvette. If any of the filter • End of roll indicator stripe on cuvette film
readings from 340 nm to 700 nm show • Source lamp misaligned/ improperly installed.
absorbance above 500 mAU, or the if the • Cuvette wheel out of alignment
293 nm filter reading is above 750 mAU, • Extremely dirty window
this error is displayed. • Bad or folded over film
• Dirty Filter
Solution
1. Clean all windows.
2. Check cuvette film is threaded properly and that red end of roll stripe is not present.
3. Perform photometer alignment per Section 4-9 of Operators Guide.
4. Check CR3 on Photometer Board to see if source lamp is on.
5. Lower thermal chamber and check that source lamp is properly installed.
6. Perform cuvette window cleaning per Operators Guide.
7. Clean and inspect optical filters.
8. If lab is closed on weekends and problems persist, enable the automatic (spent) cuvette removal feature: (OP MENU >
F5: PROCESS CONTROL > F8: MORE OPTIONS > F5: AUTO REM)

Table 2-92. Temperature Out of Range

A discrepancy has been found in the 494
cuvette temperature control system by 495
the software monitoring that system. 496
497
[494] There is a problem with the control 498
temperature • Needs calibration 499
• Defective Control thermistor 516
• Defective Cuvette Board
[495] The software is not detecting
current back from the thermal chamber • Blown heater fuse
heater • Defective heater
[496] The readings from the ambient

compensation thermistor are out of range • Defective ambient compensation thermistor
[497] The cuvette ring thermistor is out of

range
• Thermal chamber not fully seated
• The thermistor is not touching the ring
• Defective cuvette ring thermistor
[498] No current detected from the • Defective Cuvette Board.
Cuvette ring cooling fan.
• Defective Fan Fuse (AC relay board)
[499] There is a problem with reagent • Defective Fan
temperature control.
• Defective Reagent thermistor
[516] The cuvette ring temperature • Defective Refrigeration Unit
control system is sensing a problem with
the ring cooling. • Thermal chamber not fully seated
• The thermistor is not touching the ring
• Defective cuvette ring thermistor
• Defective Cuvette Board.
Solution [494]
1. Calibrate Temperature per Section 3 of Operators Guide.
2. Replace control thermistor.
3. Replace cuvette board.
Solution [495]
1. Check fuses 2C and 2D.
2. Replace heater PN 750360
Solution [496]
1. Replace air compensation thermistor PN750359
2. Replace Cuvette Board PN 751860.
Solution [497]
1. Check that cuvette ring thermistor is contacting ring and thermal chamber (WOK) is fully seated.
2. Schedule cuvettes and observe that CR4D on cuvette board is ON at least every 7-10 cuvettes. Listen for cuvette fan to
come on when LED is on.
3. Replace cuvette ring thermistor PN734931. Note: CVT Ring Thermistor Holder - PN 750441
Solution [498]
1. Check fan fuse 2B
2. Replace Fan PN750499.
Solution [499]
1. Replace refrigeration thermistor PN727528
3. Replace Refrigeration Unit PN 751275.
Solution [516]
1. Check that cuvette ring thermistor is contacting ring.
2. Schedule cuvettes and observe that CR4D on cuvette board is ON at least every 7-10 cuvettes. Listen for cuvette fan to
come on when LED is on.
3. Replace cuvette ring thermistor PN734931. Note CVT Ring Thermistor Holder - PN 750441.

Table 2-93. Unable to Form Cuvettes

The cuvette system is not forming 438
cuvettes. Refer to the minor error code 439
for reasons. 440
• Cuvette solenoid arm not installed securely
438 Air compressor not on • Bad or misadjusted pressure switch
The compressor was told to turn on but • Worn, Leaky, missing or improperly installed
the software does not see pressure diaphragm
switch activate when making a cuvette. • Leaky or loose tubing between pressure gauge
See error code 259, Table 2-58. and heat torch
• U seal solenoid out of adjustment
• Cuvette form solenoid out of adjustment
• Cuvette ring not aligned properly
• Blown compressor fuse
• Defective Compressor.
• Defective Heat Torch

• Unplugged Heat torch or defective wire going to
439 Heat torch heater open heat torch
The software is not seeing current being • Defective solder connection
returned from the heat torch. • Defective Cuvette Board.
See error code 261, Table 2-16.
• Defective or loose thermocouple
• Defective connections
440 Heat torch A/D error • Defective cuvette board.
The software is not seeing the output
from the heat torch thermocouple within
normal range.
Solution [438]
NOTE: Before beginning the following procedure, check whether the solenoid arms are loose or
mispositioned. If so, reposition and tighten, then press Reset and watch for the error message.
1. Replace the cuvette diaphragm.

2. Have the instrument make a cuvette. While the form solenoid is energized, verify that:
a. The air flow reading on the flowmeter ball drops to zero. If not, check for leaks.
b. The pressure gauge reading is greater than 15 psi during cuvette formation and its LED (located above the gauge) is lit
when the cuvette plunger is forward. Pressure gauge should hold steady at 20 psi. If not, adjust pressure regulator.
c. Pressure switch should activate LED at 15 psi (while rising). If not, adjust Allen screw on front of pressure switch with air
compressor on while pushing in the form plunger.
Solution [439]
1. Reseat connector to form assembly (P13K). Check resistance of heat torch. The resistance between pins 1 and 4 on the
form assembly should be approximately 8 ± 2 ohms. If it is not, replace the heat torch assembly.
Be sure to disconnect 24 volts before measuring resistance.
2. If error repeats, reseat the Cuvette Board and replace it.
Solution [440]
1. Check connector P/J13 to heat torch assembly.
2. Measure resistance between pins 2 and 3 on the cuvette heat torch assembly. The resistance should be 0.5 ohms. If
reading is higher replace heat torch.
3. Replace Cuvette Board.

Table 2-94. Unable to Get Photometer Reading

The measuring system uses a home and
a position sensor on the filter wheel to
synchronize the data. The measuring
system is not able synchronize the data
and signals per the minor error code.
410
410 Filter wheel position sensor not
received • Defective filter wheel position sensor.
• Defective Photometer Board
411
411 Filter wheel home sensor not being
received • Defective Home sensor
412
412 Filter wheel not spinning or incorrect
speed. (Not seeing both home and • Filter wheel motor Fuse 241C
position or not the right timing.) • Defective Dual Sensor
• Defective filter wheel motor
413 No measurement signal
(seeing reference signal but no
413
measurement signal) • Defective Photodiode
• Defective cabling
437 No reference Signal • Defective Photometer board
(seeing measurement signal but no
437
reference signal) • Defective Photodiode
• Defective cabling
• Defective Photometer board
Solution
1. Perform all alignments per Operators Guide 4-15.
2. Check minor error code and replace or check each probable cause in order.
3. See Tables 2-31 and 2-45 for further troubleshooting.
Table 2-95. Unknown Error

An unassigned error code was received • Electrical Noise generated by loose connection. 351, 424
by the computer from one of the I/O
boards.
Solution
1. Inspect the Error Log for the first error that occurred at relatively the same time {±1 minute} as the illegal error. Troubleshoot
the lowest that relates to actual subassembly with this relative time stamp.
2. Power down and reboot.
Table 2-96. User Aborted Processing

Operator deleted all processing • Operator 340, 507
segments.
Solution
To restart the instrument, press the Reset button. Some test reports may have process errors and will need to be
rerun. Press Alt/M for on-line help for this error.
Table 2-97. Vessel Track Interference
The “Vessel ready to load” sensor did not • Vessel is stuck in track 576
change state while loading vessels. • Defective sensor (766945)
• Defective Motor Control Board.
Solution
1. Press Reset and inspect loading slot for jammed vessels.
2. If vessels move freely, then replace sensor PN 766945 per Operator Guide or Replacement Procedure (in service spare
box).

Table 2-98. Vessel Wheel Full

The scheduler has scheduled all vessels • Vessel wheel is full 565
on the wheel and no more can be
scheduled until some are completed.
Solution
Press Reset after some vessels have come off the wheel.
Table 2-99. Wash Wheel Mispositioned

of steps but the encoder feedback said • Binding or interference
Solution
1. Perform Wash Wheel alignments per section 4 (Aligning) in the Xpand™ Operator’s Guide.
2. Enter Diagnostics:
(OP MENU > F7: DIAGNOSTICS > F1: ELECTROMECHANICAL > F2: SAMPLE SYSTEM > F5: HM > F8: CYCLE)
3. Observe the Wash Wheel for smooth operation.
4. Swap Motor Control Board #3 with another motor control board. If problem moves order and replace original board.
5. Replace motor/encoder PN 730105.
Table 2-100. Low Battery Voltage – Schedule Maintenance

The instrument is getting a signal from • UPS battery 423
the UPS that the UPS battery is low. • UPS
• If new install, wrong interface cable
Solution
1. Replace the UPS battery.
2. Replace the UPS.
3. If new installation, check interface cable. Do not use cable that comes from the UPS vendor: Use extra interface cable
(beige color) packaged separately PN 263100.074.

Table 2-101. Sample Carousel Movement

The motor encoder detected the wheel • User moved wheel 285, 417, 418
moving without a command from • Alignments
software.
Solution
1. Press Reset to resume operation.
2. Perform sample probe alignments (see section 4 of the Xpand™ Operator’s Guide).
Table 2-102. IMT A/D Timeout

The system is not seeing a response ! 15v DC problem 302
from the IMT A/D. ! Defective auxiliary board
! Backplane connections
Solution
1. Press Reset.
If the message reappears, continue with step 2.

2. Power down instrument and reseat Auxiliary Board.
3. Check all connections going to and from the IMT Sensor board.
4. Power up.
If problem recurs replace Auxiliary Board.
Table 2-103. IMT A/D Drift/Invalid Test Frequency

The output frequency from the IMT ! Bad connection between cable and the IMT 500
sensor to the auxiliary board is either sensor board.
501
drifting or not present. ! Blown ± 15 volt Fuse
! Unseated Auxiliary Board
! Defective IMT sensor board
! Defective auxiliary board
Solution
1. Reseat P201 on sensor board on IMT Tower.
2. Reseat J1 on sensor board.
3. Check ± 15 Volt fuse on fuse board A.
4. Reseat Auxiliary board.
5. Replace cable 766997. Refer to Xpand™ System Diagram 766900, sheet 21, zone D2.
6. Replace sensor board.
7. Replace auxiliary board.

Table 2-104. Auto Cartridge Loader Error

The autoloader detected a cartridge in the ! Cartridge detected during unloading process 515
autoloader when it went to remove a ! Dirty or sensitive flex presence sensor (750930)
cartridge from inventory.
Solution
1. Remove cartridge from auto loader and press Reset.
2. If error re-appears clean or replace flex presence sensor.
Table 2-105. Cuvette ring cooling problem

See Table 2-92
Table 2-106. Sample arm not positioned at expected location

The sample arm did not move the proper ! Sample arm motor encoder defective. 518
distance according to encoder feedback. ! Sample arm home sensor has failed. Something
is interfering with the movement of the arm.
! The sample probe needs alignment.
! Sample arm home sensor has failed.
Solution
1. Press Reset.
If error re-appears proceed to step 2.

2. Raise the right-hand (reagent) lid.
NOTE: After performing any step listed below, press Reset and check the movement of the arm; if it now moves through its
complete cycle and the message disappears, stop troubleshooting.
3. Check if anything is interfering with the movement of the arm, such as tubing or cabling restricting its movement. See
Note above.
4. Align the sample probe. See Note above.
5. Check the operation of the sample arm home sensor.
a. Go to the Sampler System Diagnostics screen.
b. Move the cursor to the Rotate Arm line in the Motors portion of this screen, then press F2: Test Mtr Only. See
Note above.
If the Home field DOES NOT change, the sensor has failed:
a. Check first to see if the sensor connector, P/J50D, is loose or unplugged,
then replace the sensor. See Note above.

Table 2-107. IMT Measurement Error

Insufficient vacuum detected while ! Vacuum Mode field is set to Cycle On/Off 525
monitoring system ! Leaks
! Auxiliary board or backplane connections
! Signal connections to AC relay board
! Fuse F7 on relay board blown
Solution
1. Press Reset.
If error re-appears continue with step 2.

2. On Water Works screen, check that Vacuum Mode field at the bottom of display is in the Always On mode.
If not, use arrow keys to move cursor to highlight field, then press Enter to toggle from Cycle On/Off to Always On
mode.
If problem remains, go to step 3.

3. Press F4: Vacuum On/Off from the Water Works menu and listen for the vacuum compressor motor to turn on and off
each time F4 is pressed.
NOTE: LEDs function as follows:
Green LED on the gauge panel comes on as vacuum gauge rises above 3 in. hg.
LED CR5C on the auxiliary board toggles on and off each time F4 is pressed.
LED CR3 on the side panel (relay board) toggles on and off each time F4 is pressed.
If the vacuum compressor can be heard:
a. If the vacuum gauge does not rise above 3 in. hg (green LED on gauge panel off), then check for leaks.
b. If LED CR5C does not toggle, suspect auxiliary board or backplane connections.
c. If LED CR7 does not toggle, suspect signal connections to AC relay board.
If the vacuum compressor cannot be heard:
a. If the gauge does not rise but LEDs CR5C (auxiliary board) and CR3 (relay board) come on, then check fuse F7
on relay board (side panel). LEDs CR5C and CR3 indicate logic signal only and do not represent fuse status or
AC voltage at the load.

Table 2-108. IMT Module Recovering

The IMT system was reporting other ! Other system problem 509
process errors while calibrating or ! Software 510
processing tests. These errors ensure all
results during this time become invalid
and are not reported.
Solution
1. Press Reset and check the Error Log for an error that occurred at the same time this error occurred. Troubleshoot this
associated error. Press Alt/M for additional help.
Hex No. Description

F Reset
interchangeable.
Table 2-109. System Error

Error allocating result buffer ! Software 519
Solution
1. Press Reset.
2. If error continues, power down instrument and reboot.
3. Report problem to the Technical Assistance Center.
Table 2-110. Sample Aborted

See Table 2-75.
Table 2-111. Vessel Feeder Timeout


Table 2-112. Sample probe failed to reliably detect fluid level

This error indicates that the fluid level ! sample probe not aligned 751
detected while descending did not match ! connectors loose on sample arm / level sense
[within a tolerance of –10 to 150 steps] circuit board
the level detected while ascending during
a level sense operation.
Solution
1. Check sample container for fluid.
If sufficient sample fluid is present, then

2. Put the sample back on the wheel and press Reset to clear error and retry.
If problem persists, then

a. Check all sample probe alignments.
b. Reseat P75A, P75B, and P75C connectors on the sample arm/level sense circuit board.
c. Replace cable PN 766916, ensure all tie wraps and clamps below baseplate are installed per replacement
procedure.
d. Download message log for additional information.
Table 2-113. No sample detected in ACMIA test vessel

This error indicates that the vessel for an ! The vessel was inadvertently disposed of during 752
ACMIA HM method [e.g., DGNA, CSA] the magnetic separation step
did not appear to contain fluid when ! Vessel gate solenoid defective
sample aspiration was performed.
! A connector / electrical problem exists with the
sampler level sense circuitry
! A problem with the sampler arm cabling, as this
sensing is performed at one extreme of travel for
the sampler arm
Solution
1. Clean and lubricate the vessel gate solenoid shaft
2. Reseat/replace the connections from the probe to the level sense board.
3. Replace the Sample Arm cables PN766916
Table 2-114. Power to instrument interrupted

This error will be present after a short • Power to the instrument was 747
power glitch or dropout. This is an interrupted.
informational message, and does not
require any intervention by the operator
other than pressing Reset and
rescheduling tests with reported process
errors.
Solution
1. Restart any tests that were in process when the power failure occurred.
Table 2-115. Optical sensor failed to detect vessel

This error indicates that the optical • Jams in vessel shuttle/track preventing vessels fro 748
sensor at the base of the flex track does reaching the sensor
not sense the presence of a vessel. • Defective sensor
Solution
1. Check for jams or obstructions in the vessel shuttle/track
2. Clean the sensor
3. Replace the sensor (766945)

Table 2-116. Vessel Low Level Detected

This error will be posted simultaneously • Need more vessels added 749
with a vessel icon whenever the vessel • Dirty or misaligned track sensor 766945
track sensor no longer detects the
presence of a vessel. This error would
normally occur as vessels are used.
Solution
1. If the LED next to the sensor is OFF when track is full of vessels, then remove sensor and clean with a soft, lint-free cloth.
2. Make sure sensor is aligned per replacement procedure 766945.601

02 Error Code Troubleshooting

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02 Error Code Troubleshooting

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Chapter 2: Error Code Troubleshooting

02/18/04 Dimension® Xpand™ Service Manual 2-1

2-2 Dimension® Xpand™ Service Manual 02/18/04

Active System Errors and Error Log Screen Description

Error Log Screen

02/18/04 Dimension® Xpand™ Service Manual 2-3

F3: SEE MINOR

2-4 Dimension® Xpand™ Service Manual 02/18/04

Error Codes/Solutions Cross Reference Table

02/18/04 Dimension® Xpand™ Service Manual 2-5

2-6 Dimension® Xpand™ Service Manual 02/18/04

02/18/04 Dimension® Xpand™ Service Manual 2-7

2-8 Dimension® Xpand™ Service Manual 02/18/04

02/18/04 Dimension® Xpand™ Service Manual 2-9

2-10 Dimension® Xpand™ Service Manual 02/18/04

02/18/04 Dimension® Xpand™ Service Manual 2-11

2-12 Dimension® Xpand™ Service Manual 02/18/04

02/18/04 Dimension® Xpand™ Service Manual 2-13

2-14 Dimension® Xpand™ Service Manual 02/18/04

02/18/04 Dimension® Xpand™ Service Manual 2-15

2-16 Dimension® Xpand™ Service Manual 02/18/04

02/18/04 Dimension® Xpand™ Service Manual 2-17

2-18 Dimension® Xpand™ Service Manual 02/18/04

02/18/04 Dimension® Xpand™ Service Manual 2-19

2-20 Dimension® Xpand™ Service Manual 02/18/04

02/18/04 Dimension® Xpand™ Service Manual 2-21

2-22 Dimension® Xpand™ Service Manual 02/18/04

Error Code Solution Tables

Warning: Keep hands clear of moving modules!

2. Does the module move without stopping? If it does, do the following:

If it does not move at all (there is no movement):

02/18/04 Dimension® Xpand™ Service Manual 2-23

Warning: Keep hands clear of moving modules!

2. Does the module move without stopping? If it does, do the following:

If it does not move at all (there is no movement):

2-24 Dimension® Xpand™ Service Manual 02/18/04

Table 2-4. “[module name] Lost Steps”

Table 2-5. “[module name] Board Test Failed”

Hex No. Description

5. Replace the board if necessary.

02/18/04 Dimension® Xpand™ Service Manual 2-25

Table 2-6. “Communication Problem or Error” or “Time Out on IOC Read”

Hex No. Description

5. Replace the board if necessary.

2-26 Dimension® Xpand™ Service Manual 02/18/04

Table 2-7. “System Error or Problem”

Hex No. Description

5. Replace the board if necessary.

Table 2-8. IMT Measurement Error: “Electrode Unstable” or “Electrode Drift”

02/18/04 Dimension® Xpand™ Service Manual 2-27

Table 2-9. Host Communication

2-28 Dimension® Xpand™ Service Manual 02/18/04

Table 2-10. “Critical Time Missed” or “Block Time Missed”

Hex No. Description

5. Replace the board if necessary.

Table 2-11. “Failed to Recover After Process Error”

02/18/04 Dimension® Xpand™ Service Manual 2-29

Table 2-12. “IMT Failed Autocalibration”

Table 2-13. IMT Sample/Standard Fluid Detect Failure

2-30 Dimension® Xpand™ Service Manual 02/18/04

Table 2-14. “IMT Fluid Detected When Air Expected”

02/18/04 Dimension® Xpand™ Service Manual 2-31

Table 2-15. “Floppy not Ready” Errors

Table 2-16. “Heat Torch Timed Out”